Systems and methods for electromagnetic forming of containers

ABSTRACT

Systems and methods of forming articles using electromagnetic radiation are disclosed. In some aspects, the system includes a plurality of forming modules movably mounted relative to an infeed mechanism. The infeed mechanism is configured to supply pre-form articles to the plurality of forming modules, and each of the plurality of forming modules includes a multi-segment mold disposed about an electromagnetic coil. The electromagnetic coil is configured to impart an electromagnetic force on the pre-form articles when supplied with electrical energy that urges the pre-form articles into contact with the multi-segment mold to produce the formed containers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. Non-Provisional applicationSer. No. 16/107,249, filed Aug. 21, 2018, issued May 17, 2022 as U.S.Pat. No. 11,335,486, which is a divisional of U.S. application Ser. No.15/307,161, filed Oct. 27, 2016, now U.S. Pat. No. 10,081,045, issuedSep. 25, 2018, which is a National Stage Entry of InternationalApplication No. PCT/US2015/029084, filed on May 4, 2015, which claimsthe benefit of U.S. Provisional Application No. 61/988,214, filed May 4,2014, the contents of each of which are hereby incorporated by referenceherein in its entirety.

FIELD OF THE INVENTION

The present disclosure relates generally to manufacturing articles suchas beverage containers, and more particularly, to systems and methods offorming containers using electromagnetic processing.

BACKGROUND

In conventional production of metal containers, a large number ofmanufacturing operations are required to produce common features.Pre-form containers, such as those produced by a drawn-wall ironingprocess or an impact-extrusion process, typically require a number offorming operations including expanding, necking, flanging, body shaping,embossing, threading, trimming, threading, etc. to produce a finishedcontainer. Moreover, each of these forming operations generally requiresmultiple stages to produce the desired feature. At each stage, acold-forming or cold-working step is performed by contacting thecontainer with specific tooling such as dies.

Necking a container generally requires between approximately 7 and 17die-necking stages to produce, depending on properties of the containersuch as wall thickness and neck geometry. Flanging the containergenerally requires one or more roll-forming stages. Shaping the body ofa container generally requires multiple die-reduction and die-expansionstages, with the number of stages increasing as the complexity of thefinal geometry increases. Embossing or debossing generally requires onestage of rolling against a tool, or pressure forming into a mold.Threading generally requires at least one roll-forming stage. Trimminggenerally requires one stage, and multiple trimming operations may berequired when multiple necking and shaping stages are performed. Forexample, one trim may be required after every approximately 8 to 12reducing or expanding stages. Thus, production of a completely finishedcontainer can require 50 or more forming stages.

Conventional machine arrangements for bottle and can manufacturinginclude a plurality of processing or forming modules extending in asingle process line that is typically linear. This is generally referredto as a “machine line.” Containers are passed through the machine lineuntil reaching a desired stage of manufacture. Each module in themachine line receives a container and completes only a single formingstage on the container before passing the container to an adjacentmodule. Thus, such arrangements generally require a large amount ofspace in a warehouse, factory, or other location. What is more, eachmodule in the machine line also generally increases operating costs forthe system because each module requires individualized maintenance andprovides additional points of potential failure.

Another downside of conventional machine arrangements is that eachcold-form stage alters the physical properties of the containermaterial, typically making the material more brittle. Thus, thestructural integrity of the article is reduced, and additionaloperations such as heating or lubricating the container may be requiredto counteract these altered properties.

As an alternative to cold-forming, metal straight-wall pre-form articlesor other tubes can be subjected to magnetic pressure, and therebyformed, using a wound-wire electromagnetic coil inserted into thecontainer. When a large electrical pulse is released through the coil,an induced current pulse is produced in the wall of the container. Theresulting magnetic pressure can be used to force the wall of thecontainer outward, thereby forming the container. A mold is sometimesused to aid in shaping the container.

These magnetic-pressure systems are generally low-speed, low-throughput,and batch systems. These systems also have significant drawbacks such asinconsistent forming of articles, an inability to produce fine-detailembossing, an inability to produce smooth-sided containers, an inabilityto produce certain container geometries, or the like. For example,certain container geometries cannot be achieved using electromagneticsystems because the wound-wire coils cannot deliver sufficientelectromagnetic force near the lower sidewall of the container due toinsufficient clearance between the domed bottom of the can and thesidewall for the electromagnetic coil. One method attempting to curethis deficiency is disclosed in U.S. Pat. No. 5,730,016 entitled “Methodand Apparatus for Electromagnetic Forming of Thin Walled Metal.” Thesystem disclosed therein includes an intermediate conductor that isthinner than the coil and, thus, can extend more proximate the domedbottom of the article. The wound-wire coil induces a current into theintermediate conductor, which in turn applies an electromagnetic forceon the article. However, this produces a number of drawbacks including aloss of forming power between the coil and the article due to inductionof current in the intermediate conductor, a non-uniform force applied inthe radial direction due to the required slit(s) in the intermediateconductor, and/or a sizing issue due to the coil and intermediateconductor needing to fit inside of the pre-form article.

Thus, a need exists for systems and methods providing high-speed,high-throughput electromagnetic forming of containers. A further needexists for systems and methods that use electromagnetic energy toconsistently form containers having irregular shapes. A yet further needexists for systems and methods that can directly apply electromagneticforces to low-clearance areas of containers.

SUMMARY

According to aspects of the present disclosure, a rotary-turret systemfor forming a plurality of formed containers from a respective pluralityof pre-form articles using electromagnetic energy includes a rotaryturret, a charging circuit, and a discharge-control mechanism. Therotary turret includes a plurality of forming modules. The formingmodules are disposed about the periphery of the rotary turret. Eachforming module includes a multi-segment mold disposed about anelectromagnetic coil. The multi-segment mold has a plurality ofsegments. Each segment includes an inner surface. The plurality of innersurfaces defines a desired shape of the formed containers. Theelectromagnetic coil is configured to impart an electromagnetic force onthe pre-form articles when supplied with electrical energy. Theelectromagnetic force is configured to urge the pre-form articles intocontact with the inner surfaces of the multi-segment mold to produce theformed containers. The charging circuit is configured to supply theelectrical energy to the rotary turret. The discharge-control mechanismis operatively coupled to the rotary turret and the charging circuit.The discharge-control mechanism is configured to selectively actuatedischarge of the electrical energy from the charging circuit to apredetermined one of the plurality of forming modules. The rotary turretcontinually rotates during forming of the plurality of formedcontainers.

According to further aspects of the present disclosure, a method forelectromagnetic forming of formed containers using a rotary turret has aplurality of forming modules disposed about the periphery of the rotaryturret includes the acts of receiving a pre-form article from anupstream process in a respective one of the forming modules, disposingthe pre-form article about an electromagnetic coil, securing amulti-segment mold about the pre-form article, and supplying a firstelectrical energy to the electromagnetic coil to produce anelectromagnetic force after securing the multi-segment mold. Theelectromagnetic coil is disposed on the forming module. Theelectromagnetic coil is configured to impart an electromagnetic force onthe pre-form article when supplied with electrical energy. Themulti-segment mold includes a plurality of segments. Each of theplurality of segments includes an inner surface. The plurality of innersurfaces defines a desired shape of the formed containers. Theelectromagnetic force is configured to urge the pre-form article intocontact with the inner surfaces of the multi-segment mold. Contactbetween the pre-form article and the inner surfaces of the multi-segmentmold produce one of the formed containers. The disposing, securing, andsupplying steps occur while the rotary turret continually rotates.

According to yet further aspects of the present disclosure, a system forforming a plurality of formed containers from a plurality of pre-formarticles using electromagnetic energy includes a plurality of formingmodules, a charging circuit, and a discharge control mechanism. Theplurality of forming modules is movably mounted relative to an infeedmechanism. The infeed mechanism is configured to supply pre-formarticles to the plurality of forming modules. Each of the plurality offorming modules includes a multi-segment mold disposed about anelectromagnetic coil. The multi-segment mold has a plurality ofsegments. Each of the plurality of segments includes an inner surface.The plurality of inner surfaces defines a desired shape of the formedcontainers. The electromagnetic coil is configured to impart anelectromagnetic force on the pre-form articles when supplied withelectrical energy. The electromagnetic force is configured to urge thepre-form articles into contact with the inner surfaces of themulti-segment mold to produce the formed containers. The chargingcircuit is configured to supply the electrical energy to the pluralityof forming modules. The discharge-control mechanism is operativelycoupled to the plurality of forming modules and the charging circuit.The discharge-control mechanism is configured to selectively actuatedischarge of the electrical energy from the charging circuit to apredetermined forming module.

According to still yet further aspects of the present disclosure, a moldsystem includes a first plate disposed opposite a second plate, and amulti-segment mold. Each of the first plate and the second plateincludes a plurality of slots thereon. Each of the plurality of slots inthe first plate corresponds to a respective one of the plurality ofslots on the second plate. The multi-segment mold extends the distancebetween the first plate and the second plate. The multi-segment mold hasan open state and a closed state. The multi-segment mold includes aplurality of segments. Each of the plurality of segments has one of aplurality of inner surfaces thereon. The plurality of segments iscooperatively arranged such that the plurality of inner surfaces definesa volume when in the closed state. Each of the plurality of segments ofthe multi-segment mold includes a first end disposed proximate the firstplate and a second end proximate the second plate. The first end and thesecond end of each of the plurality of segments includes slot followers.Each of the slot followers is configured to engage one of the pluralityof slots. Each of the plurality of slots is shaped such that engagementof the slot followers with the respective slots guide movement of theplurality of segments between the open state and the closed state wheneach of the plurality of segments moves relative to the first plate andthe second plate.

According to additional aspects of the present disclosure, anelectromagnetic coil assembly includes a bottom cap and milled helicalwindings. The milled helical windings are electrically coupled to thebottom cap. The bottom cap and the milled helical windings areconfigured to be coupled to a charging circuit. The helical coil isconfigured to exert an electromagnetic force when an electrical energyis passed through the milled helical windings. The milled helicalwindings are created by milling a generally cylindrical tube ofconductive material.

According to yet additional aspects of the present disclosure, a methodof making an electromagnetic coil includes the acts of assembling a topcap, a winding tube, a bottom cap, and a return conductor, pouring acurable material into a cavity formed by the top cap, the winding tube,the bottom cap, and the return conductor, and milling the winding tubeto form helical windings. The assembling includes securing the top capto a first end of the winding tube, securing the bottom cap to a secondend of the winding tube, and securing the return conductor to the bottomcap. The second end is opposite the first end. The top cap iselectrically coupled to the winding tube. The bottom cap is electricallycoupled to the winding tube. The return conductor is electricallycoupled to the bottom cap. The windings are formed by removing portionsof the winding tube.

According to still yet additional aspects of the present disclosure, anelectromagnetic coil includes a top cap, a bottom cap, helical windings,and a return conductor. The bottom cap is shaped to accommodate a domedbottom of a pre-form article. The helical windings extend between thetop cap and the bottom cap. The helical windings are electrically couplethe top cap and the bottom cap. The helical windings define a generallycylindrical cavity therein. Each of the helical windings has across-sectional profile. The cross-sectional profiles include generallyflat edges proximate the cavity. The return conductor is electricallycoupled to the bottom cap. The top cap, helical windings, bottom cap,and return conductor form an electrical circuit. The electrical circuitis configured to be electrically coupled to a charging circuit.

Aspects of the present disclosure also provide a variable-speedstarwheel for transferring articles including a driving mechanism, a camsurface, and an arm. The driving mechanism is configured to rotate aboutan axis of rotation. The cam surface has variable radial distance fromthe axis of rotation. The variable radial distance has a first radialdistance extending a first distance away from the axis of rotation at afirst angular position. The variable radial distance also has a secondradial distance extending a second distance away from the axis ofrotation at a second angular position. The second angular position isspaced a distance from the first angular position. The arm is coupled tothe driving mechanism. The arm includes a pivot mechanism, a pocket, anda cam follower. The pivot mechanism is coupled to the driving mechanism.The pivot mechanism provides pivotable movement of the arm relative tothe driving mechanism. The pivot mechanism is spaced a distance from thepocket. The pocket is configured to releasably receive the articles. Thecam follower is configured to engage the cam surface. Engagement of thecam follower with the cam surface at the first angular position disposesthe arm at a first angle. Engagement of the cam follower with the camsurface at the second angular position disposes the arm at a secondangle. The second angle is different than the second angle.

Aspects of the present disclosure yet also provide an arm for use in avariable-speed starwheel to transfer articles including a member and acam follower. The member has a first end opposite a second end. Thefirst end has a pivot mechanism configured to be coupled to a drivingmechanism. The pivot mechanism is configured to provide pivotablemovement of the arm relative to the driving mechanism. The second endhas a pocket configured to releasably receive the articles. The camfollower is configured to engage a cam surface. The cam follower iscoupled to the member such that engagement of the cam follower with acam surface is configured pivotably move the arm about the pivotmechanism.

Aspects of the present disclosure still yet also provide avariable-speed starwheel for transferring articles including a drivingmechanism, a cam surface, and an arm. The driving mechanism isconfigured to rotate about an axis of rotation. The cam surface hasvariable radial distance from the axis of rotation. The variable radialdistance has a first radial distance extending a first distance awayfrom the axis of rotation at a first angular position. The variableradial distance also has second radial distance extending a seconddistance away from the axis of rotation at a second angular position.The second angular position is spaced a distance from the first angularposition. The arm is coupled to the driving mechanism. The arm includesa first portion and a second portion. The second portion is slidablymounted on the first portion. The first portion is attached to thedriving mechanism. The second portion includes a pocket and a camfollower. The pocket is configured to releasably receive the articles.The cam follower is configured to engage the cam mechanism. Engagementof the cam follower with the cam surface at the first angular positiondisposes the arm at a first distance from the axis of rotation.Engagement of the cam follower with the cam surface at the secondangular position disposes the arm at a second distance from the axis ofrotation. The first distance is different than the second distance.

Aspects of the present disclosure further also provide a variable-speedstarwheel for transferring articles including a driving mechanism, apocket, and a movement means. The driving mechanism is configured torotate about an axis of rotation. The pocket is coupled to the drivingmechanism. The pocket is configured to releasably receive the articles.The movement means is configured to dispose the pocket at a firstdistance from the axis of rotation when the pocket is at a first angularposition and to dispose the pocket at a second distance from the axis ofrotation when the pocket is at a second angular position.

BRIEF DESCRIPTION

FIG. 1 illustrates a schematic diagram of a system for electromagneticforming of articles, according to aspects of the present disclosure.

FIG. 2A illustrates a perspective view of a rotary-turret system forelectromagnetic forming of articles from a first side, according toaspects of the present disclosure.

FIG. 2B illustrates a perspective view of the rotary-turret system ofFIG. 2A from a second side, opposite the first side.

FIG. 2C illustrates an example pre-form article.

FIG. 2D illustrates an example formed container having been shaped,necked, and flanged using electromagnetic forming.

FIG. 2E illustrates an exemplary formed container having been expanded,necked, flanged, and embossed using electromagnetic forming.

FIG. 3A illustrates a perspective view of an example forming module foruse in the rotary-turret system of FIGS. 2A-B, according to aspects ofthe present disclosure.

FIG. 3B illustrates a cross-sectional view of the forming module of FIG.3A when disposed in a first position.

FIG. 3C illustrates a cross-sectional view of the forming module of FIG.3A when disposed in a second position.

FIG. 3D illustrates a side view of the forming module of FIG. 3C.

FIG. 4A illustrates a cross-sectional view of the forming module of FIG.3A when the mold is in an open position.

FIG. 4B illustrates an end view of the forming module of FIG. 4A, withthe outer plate removed.

FIG. 4C illustrates an end view of the forming module of FIG. 4A.

FIG. 4D illustrates a cross-sectional view of the forming module of FIG.3A when the mold is in a closed position.

FIG. 4E illustrates an end view of the forming module of FIG. 4D, withthe outer plate removed.

FIG. 4F illustrates an end view of the forming module of FIG. 4D.

FIG. 5 illustrates a cross-sectional view of an electromagnetic coil andmulti-segment mold, according to aspects of the present disclosure.

FIG. 6 illustrates a partial-cross-sectional view of an electromagneticcoil, according to aspects of the present disclosure.

FIG. 7A illustrates an exploded view of components of theelectromagnetic coil of FIG. 6 , according to aspects of the presentdisclosure.

FIG. 7B illustrates a cross-sectional view of the assembled componentsof FIG. 7A.

FIG. 7C illustrates a cross-sectional view of the assembled componentsof FIG. 7A after milling a helical coil.

FIG. 7D illustrates a side view of the electromagnetic coil of FIG. 7C,according to aspects of the present disclosure.

FIG. 8 illustrates a process timing schematic for an exemplaryrotary-turret system using electromagnetic forming, according to aspectsof the present disclosure.

FIG. 9 illustrates an electrical schematic of an exemplary formingsystem, according to aspects of the present disclosure.

FIG. 10A illustrates an example of a schematic of a system including amoving spark-gap mechanism, according to aspects of the presentdisclosure.

FIG. 10B illustrates an example of a schematic of a system including amoving inductive-coil mechanism, according to aspects of the presentdisclosure.

FIG. 11A illustrates a side view of a variable-speed starwheel,according to aspects of the present disclosure.

FIG. 11B illustrates a side view an arm for use in the variable-speedstarwheel of FIG. 11A from a first side.

FIG. 11C illustrates a side view an arm for use in the variable-speedstarwheel of FIG. 11A from a second side.

FIG. 11D illustrates a perspective view of a variable-speed starwheel,according to aspects of the present disclosure.

FIG. 11E illustrates a side view of the variable-speed starwheel of FIG.11D.

FIG. 1 IF illustrates a perspective view of a variable-speed starwheel,according to aspects of the present disclosure.

FIG. 11G illustrates a side view of the variable-speed starwheel of FIG.11F.

FIG. 12A illustrates a perspective view of a bottom mold segment of amold having flexural hinges.

FIG. 12B illustrates the bottom mold segment of FIG. 12A from a secondperspective view.

FIG. 12C illustrates an end view of a multi-segment mold including thebottom mold segment of FIG. 12A coupled to other segments using flexuralhinges.

FIG. 13A illustrates a first perspective view of a belt-driven loadingmechanism.

FIG. 13B illustrates a second perspective view of the belt-drivenloading mechanism of FIG. 13A.

FIG. 14 illustrates a cross-sectional view of an electromagnetic formingcoil, according to aspects of the present disclosure.

DETAILED DESCRIPTION

While this invention is susceptible of embodiment in many differentforms, there is shown in the drawings and will herein be described indetail preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated. For purposes ofthe present detailed description, the singular includes the plural andvice versa (unless specifically disclaimed); the words “and” and “or”shall be both conjunctive and disjunctive; the word “all” means “any andall”; the word “any” means “any and all”; and the word “including” means“including without limitation.”

According to aspects of the present disclosure, anelectromagnetic-forming system is configured to perform one or moreforming operations such as trimming, flanging, threading, embossing,shaping, expanding, and necking on an article. These forming operationsare accomplished using a multi-segment mold, air pressure and/or vacuum,and one or more electromagnetic pulses delivered using anelectromagnetic coil.

Beneficially, electromagnetic-forming systems and methods in accord withthe present disclosure significantly reduce the number of stagesrequired to produce finished articles such as thin-walled, metalcontainers. These systems and methods can perform a forming operationsuch as necking in a single stage, rather than the multiple stagesrequired by typical cold-form systems. Moreover, these systems andmethods can also perform one or more operations such as expanding andembossing in a single stage. As such, the systems and methods requiresignificantly fewer stages to achieve a fully formed container, thusreducing the number of machines needed in a machine line. The reductionof machines in the machine line also reduces certain costs associatedwith manufacture such as reducing space needed to house the machine lineand reduced maintenance costs. Further, as discussed above, fewercold-forming stages reduces the brittleness associated withwork-hardening caused by many cold-forming stages. Beneficially, thisreduced brittleness allows for more complex geometries, such as highlyexpanded and complex shaped and embossed articles that may not bepossible using many cold forming stages that may result in cracking ofthe more brittle work-hardened metal. Further, much higher expansionsare possible with high-speed electromagnetic forming compared tomulti-stage cold forming systems. Yet another benefit of aspects of thepresent disclosure is to produce formed containers 218 having a wallthickness that is thinner than containers formed using cold-forming,resulting in lower metal cost per formed container 218.

Additionally, electromagnetic-forming systems and methods in accord withthe present disclosure provide for high-speed, continuous processing ofarticles, while producing consistently formed containers fromthin-walled pre-form articles.

Aspects of the present disclosure also provide for low-profileelectromagnetic coils that can extend into narrow clearances of pre-formarticles to provide direct and efficient electromagnetic forming of thelower sidewall of pre-form articles. In some aspects, these low-profilecoils include milled or machined windings.

Aspects of the present disclosure also provide for fine-detailpatterning on formed containers through, for example, use of amulti-segment mold.

Aspects of the present disclosure provide for trimming pre-form articlesusing electromagnetic forming. According to some aspects, the pre-formarticle is trimmed using, for example, a sharp edge in the mold andusing electromagnetic force to contact the pre-form article with thesharp edge.

Aspects of the present disclosure provide for threading pre-formarticles using electromagnetic forming. The articles formed may be cans,any suitable food or beverage containers, jars, bottles, or any othersuitable articles of manufacture. The articles may be formed ofmaterials capable of responding to an electromagnetic field such as ametal, metal alloy, any other suitable material, combinations thereof,and the like. It is contemplated that aspects of the present disclosuremay also be applicable to articles that do not generally respond to anelectromagnetic field such as polymers. Each of the articles has an openend opposite a closed end and at least one sidewall bridging the openend and the closed end.

Referring now to FIG. 1 , a schematic illustration of anelectromagnetic-forming system 100 is shown. The electromagnetic-formingsystem 100 includes a charging circuit 102, a discharge-controlmechanism 104, a rotary-turret system 106, a vacuum system 108, and acompressed-gas system 110. The charging circuit 102 delivers energy tothe rotary-turret system 106 in a series of high-energy impulses. Thecharging circuit 102 can be, for example, a bank of capacitorsconfigured to collect energy from an electrical grid. Thedischarge-control mechanism 104 selectively discharges the energy fromthe charging circuit 102 and delivers the energy to the rotary-turretsystem 106. The rotary-turret system 106 is configured to receivepre-form articles 216, perform at least one forming operation thereonusing electromagnetic energy supplied by the charging circuit 102, andpass the formed container 218 downstream for further processing orpackaging. The vacuum system 108 is coupled to the rotary-turret system106 to selectively evacuate volumes within the rotary-turret system 106.The compressed-gas system 110 is coupled to the rotary-turret system 106to selectively pressurize volumes within the rotary-turret system 106.

Referring now to FIGS. 2A and 2B, an example rotary-turret system 106for use in the electromagnetic-forming system 100 is shown. Theillustrated rotary-turret system 106 provides for high-speed,high-throughput, and continuous processing of articles usingelectromagnetic forming. The rotary-turret system 106 includes an infeedstarwheel 202, a forming turret 204, an outfeed starwheel 206, a loadingcam 210, and a mold cam 212. The infeed starwheel 202, forming turret204, and outfeed starwheel 206 are cooperatively arranged to form aprocess line. Each of the infeed starwheel 202 and the outfeed starwheel206 includes a plurality of starwheel pockets 214 configured to receivearticles at a predetermined stage of manufacture. The starwheel pockets214 are disposed generally regularly about the periphery of the infeedstarwheel 202 and outfeed starwheel 206. The forming turret 204 includesa plurality of forming modules 208 configured to perform at least oneforming operation on the articles. The forming modules 208 are disposedgenerally regularly about the periphery of the forming turret 204.

The infeed starwheel 202 receives pre-form articles 216 from upstreamstarwheels or track-work using starwheel pockets 214, and then feedseach pre-form article 216 into a respective forming module 208 on theforming turret 204. In some embodiments, the infeed starwheel 202 hasdynamically variable speed, pitch spacing, combinations thereof, and thelike. Beneficially, such a dynamically-variable infeed starwheel 202allows for receiving an article at one speed and depositing the articleat another speed in systems that require a large speed or pitch changeduring processing, as will be described in further detail in relation toFIG. 11 below.

The forming turret 204 counter-rotates relative to the infeed starwheel202 and uses electromagnetic energy to perform at least one formingoperation on the pre-form article 216 while continually rotating. Theforming turret 204 includes the plurality of forming modules 208disposed about its periphery. Each forming module 208 receives apre-form article 216 from the infeed starwheel 202 and performs at leastone forming operation on the article while the forming turret 204continually rotates. The at least one forming operation can be completedin a variety of angular distances that are less than one revolution ofthe forming turret 204, such as about 180°, about 270°, or the like. Itis contemplated that the angular distances may be more than onerevolution of the forming turret 204, such as about 540°, about 630°, orthe like.

The outfeed starwheel 206 counter-rotates relative to the forming turret204 and receives formed containers 218 from the forming modules 208using starwheel pockets 214. The outfeed starwheel 206 then passes theformed containers 218 downstream for further processing or packaging. Asdiscussed above with respect to the infeed starwheel 202, the outfeedstarwheel 206, in some embodiments, may have dynamically variable speed,pitch spacing, combinations thereof, and the like.

The loading cam 210 is disposed on a first side of the forming turret204 and selectively actuates loading and unloading of the articles ontoan electromagnetic coil 306 (FIGS. 3A-D). The mold cam 212 is disposedon a second side of the forming turret 204 that is opposite the firstside and selectively actuates opening and closing of a multi-segmentmold 308 (FIGS. 4A-F). The loading cam 210 and the mold cam 212 aregenerally fixed during operation of forming turret 204 such that theforming turret 204 rotates relative to the loading cam 210 and the moldcam 212. It is contemplated that the loading cam 210 and the mold cam212 may be disposed on a single side of the forming turret and may evenbe surfaces disposed on a single member.

Referring now to FIG. 2C, a pre-form article 216 is shown. The pre-formarticle 216 includes a domed bottom 262 with a sidewall 264 extendingtherefrom. The pre-form article 216 is generally produced from adrawn-wall ironing process or an impact-extrusion process. The pre-formarticle 216 includes a generally uniform initial diameter D1 throughoutthe length of the pre-form article 216. The sidewall thickness may varyalong the length of the article to optimize material usage relative tothe structural performance effects of the final geometry.

Referring now to FIG. 2D, an example formed container 218 is shown. Theformed container 218 may be produced by, for example, shaping, necking,and flanging the pre-form article 216. The formed container 218 includesthe domed bottom 262 and a sidewall 284. The formed container 218includes a plurality of diameters including an opening diameter D2, anupper diameter D3, a midsection diameter D4, and a lower diameter D5. Inthe illustrated example, the formed container 218 includes an hourglassshape where the upper diameter D3 and lower diameter D5 are generallylarger than the midsection diameter D4. In some aspects, the openingdiameter D2 is generally the same as the initial diameter D1. Morecomplex shapes may also be produced. A container may have any number ofalternating small and large diameters. None circular cross sections andasymmetric shapes are also possible.

Referring now to FIG. 2E, an exemplary formed container 218′ having anembossed pattern is shown. The formed container 218′ may be produced by,for example, expanding, necking, flanging, and embossing the pre-formarticle 216 of FIG. 2C. The formed container 218′ includes the domedbottom 262 and a sidewall 294. The formed container 218′ includes aplurality of diameters including an opening diameter D6, a sidewalldiameter D7, and a bottom diameter D8. In the illustrated example, theuniformly expanded sidewall 294 has a sidewall diameter D7 that islarger than the opening diameter D6 or the bottom diameter D8. Thesidewall 294 also includes embossing 296 or raised ridges. The embossing296 is a positive pattern formed by, for example, contact between apattern 309 (see, e.g., FIG. 3A) disposed on the inner surface 412 of amulti-segment mold 308 (see FIGS. 4A-4F) and the sidewall 294.

Referring now to FIGS. 3A-D, an example forming module 208 having aloading portion 301 and a forming portion 305 is shown. The loadingportion 301 includes a loading mechanism 302 and a loading-mechanismactuator 304. The loading mechanism 302 is configured to releasablyreceive a pre-form article 216 and, when actuated, move the articlebetween a first position that is distal the forming portion 305 and asecond position that is proximal the forming portion 305.

The forming portion 305 includes the electromagnetic coil 306, themulti-segment mold 308, a mold actuator 310, an inner plate 312 and anouter plate 314. The multi-segment mold 308 extends between and issupported by the inner plate 312 and the outer plate 314. Themulti-segment mold 308 is disposed generally about the electromagneticcoil 306 and may include a pattern 309 on the interior of themulti-segment mold 308 to be imprinted on the formed container 218.

During operation, the loading mechanism 302 receives a pre-form article216 while disposed in the first position. The loading-mechanism actuator304 then urges the loading mechanism 302 away from the second positionto load the pre-form article 216 onto the electromagnetic coil 306. Themold actuator 310 urges the multi-segment mold 308 to close around theelectromagnetic coil 306 and the pre-form article 216. After themulti-segment mold 308 is closed, a forming operation is performed onthe pre-form article 216 to produce a formed container 218. After theforming operation is complete, the mold actuator 310 urges themulti-segment mold 308 open and the loading-mechanism actuator 304 urgesthe loading mechanism 302 from the second position to the firstposition, removing the formed container 218 from the electromagneticcoil 306. After the loading mechanism 302 reaches the first position,the formed container 218 is removed from the loading mechanism 302 by,for example, the outfeed starwheel 206.

The loading mechanism 302 can be any mechanism capable of releasablyreceiving a pre-form article 216 from the infeed starwheel 202. Theloading mechanism 302 includes an article-engaging surface 322 with anopening coupled to the vacuum system 108 (not shown). Thearticle-engaging surface 322 forms a seal with a domed bottom portion ofthe pre-form article 216 such that a selectively-applied vacuum securesthe pre-form article 216 to the loading mechanism 302. In someembodiments, mechanical features directly engage the pre-form article216 to releasably secure the article to the loading mechanism 302. Forexample, in some embodiments, a “gripper” is used, to apply a pinchingforce to the pre-form article 216. The mechanical features can beactuated by, for example, a cam element or other non-rotational feature.

The loading-mechanism actuator 304 includes an actuator carriage 342 anda loading-mechanism carriage 344. The actuator carriage 342 is coupledto the loading-mechanism carriage 344 using a drive belt 346 such thatmovement of the actuator carriage 342 moves the loading-mechanismcarriage 344 and vice versa.

The actuator carriage 342 includes a loading cam follower 348 thatcontacts the cam surface of the loading cam 210 during rotation of theforming turret 204. Contact between the loading cam 210 and the loadingcam follower 348 urges the actuator carriage 342 downward, which in turnurges the loading-mechanism carriage 344 toward the electromagnetic coil306 and the multi-segment mold 308. The loading-mechanism carriage 344is spring loaded to urge the loading mechanism 302 toward the firstposition when the loading cam 210 disengages the loading cam follower348. In some aspects, the loading cam 210 is a grooved cam or slottedcam. The grooved cam includes two cam surfaces spaced a distance apart.The first cam surface is configured to urge the actuator carriage 342upward downward, which in turn urges the loading-mechanism carriage 344toward the electromagnetic coil 306. The second cam surface isconfigured to urge the actuator carriage 342 downward, which in turnurges the loading-mechanism carriage 344 away from the electromagneticcoil.

Referring now to FIGS. 4A-F, a multi-segment mold 308 is shown in twostates of operation. FIGS. 4A-C depict the multi-segment mold 308 in afirst state where the mold is open. FIGS. 4D-F depict the multi-segmentmold 308 in a second state where the mold is closed. The multi-segmentmold 308 uses a mold or forming die having multiple segments to provideeasy removal of formed containers 218 without damage to the surface ofthe formed containers 218. The number of segments required can be varieddepending on, for example, the level of detail needed for embossingpatterns, material to be molded, geometries for the formed container218, etc. Two-segment molds may be used, for example, on metalcontainers having smooth sidewalls and no threading features. However,metal containers having an embossed pattern, threaded features, orcertain other geometries may be scratched, deformed, or otherwisedamaged during the opening and closing action of the mold due to thetangential, sheering movement in the direction of opening along theparting lines of the mold. Beneficially, three or more mold segments maybe used to eliminate the tangential movement along the parting lines,allowing for fine-detail embossing patterns or other features on metalcontainers without significantly damaging the formed container 218during separation of the mold.

In the illustrated embodiment, the multi-segment mold 308 includes threesegments 402 a-c. Each segment includes at least one slot follower 404a-c and a mold insert 406 a-c. The slot followers 404 a-c are disposedat each end of the mold segments 402 a-c and fit within respective slots408 a-c formed on the inner plate 312 and the outer plate 314. The slots408 a-c guide movement of the multi-segment mold 308 during opening andclosing of the multi-segment mold 308. In some aspects, link arms areused in place of the slots 408 a-c and slot followers 404 a-c to guidemotion of the multi-segment mold 308 during opening and closing. Each ofthe link arms include a first end pivotably and/or slidably attached toa respective inner plate 312 or outer plate, and a second end pivotablyand/or slidably attached to a respective one of the segments 402 a-c.

In some embodiments, the segments 402 a-c of the multi-segment mold 308are coupled using hinges 410. The hinges 410 connect the segments 402a-c such that movement of any of segments 402 a-c produces movement ofthe remaining segments 402 a-c. In the illustrated embodiment, downwardmovement of the bottom mold segment 402 c causes generally outwardmovement of the left and right mold segments 402 a,b due to contact ofslot followers 404 a,b with their respective slots 408 a,b. Similarly,upward movement of the bottom mold segment 402 c causes generally inwardmovement of the left and right mold segment 402 a,b. In some aspects,the hinges 410 include a flexural hinge mechanism 1202 a,b (FIGS.12A-12C).

Other slot geometries may be used to achieve desired kinematics. Forexample, the opening positions, velocities, accelerations, or forcerelationships of segments of the multi-segment mold 308 relative to thedownward movement of the lower mold segment 402 c may be altered usingdifferent slot geometries. In some aspects, the slots 408 a-c may bereplaced by guide arms having one end pivotably attached to the innerplate 312 or the outer plate 314 at the desired center of rotation forthe respective mold segment 402 a,b to produce the same or similarmotion produced by the slots 408 a,b. For example, the guide arms beingattached at the center of an arc formed by the respective slot 408 a,bproduces the same movement as the illustrated slot 408 a,b and slotfollower 404 a,b arrangement.

The mold inserts 406 a-c, when the mold is closed, form the perimeter ofthe formed container 218 and have a respective portion of the pattern309 (FIG. 3A) on the inner surface 412 of the mold insert 406 a-c. Themold inserts 406 a-c can be formed from any suitable material includingmetals, metal alloys, polymers, ceramics, combinations thereof, or thelike. In some aspects, the mold inserts 406 a-c are formed from DELRIN®,nylon, polycarbonate, glass-filled nylon, glass-filled DELRIN®. In theillustrated embodiment, each mold insert 406 a-c covers about 120° orabout one-third of the circumference of the formed container 218. It iscontemplated that the angles covered by each mold insert 406 a-c may benon-uniform such as a first mold insert 406 a covering about 90°, asecond mold insert 406 b covering about 90°, and a third mold insert 406c covering about 180°.

As shown in FIG. 5 , the mold inserts 406 a-c include one or moretubular cavities 502 therethrough, with openings on the inner surface412 of the mold insert 406. This allows a vacuum to be applied to theouter surface of the pre-form article 216. Beneficially, applying avacuum to the outer surface of the pre-form article 216 allows lesselectrical energy to be used to produce the formed container 218 andhelps inhibit surface aberrations on the formed container 218 that maybe caused by trapped air between the sidewall of the formed container218 and the inner surface 412 of the mold. Additionally, application ofthe vacuum also assists in securing closure of the multi-segment mold308 to ensure there is no unwanted spacing in the pattern 309 along theparting lines separating adjacent mold inserts 406 a-c. Beneficially,the vacuum can be applied using the loading mechanism 302, or themulti-segment mold 308 may be coupled to the vacuum system 108.

Referring now to FIG. 6 , the electromagnetic coil 306 includes a topcap 362, helical windings 364, a bottom cap 366, a return conductor 368,a core 370, and an insulating sleeve 372. The top cap 362, helicalwindings 364, bottom cap 366, and return conductor 368 are each formedfrom one or more conductive materials and form an electrical paththrough the electromagnetic coil 306. The top cap 362 is electricallycoupled to a first end 360 of the helical windings 364. The returnconductor 368 is electrically coupled to a second end 361 of the helicalwindings 364 using the bottom cap 366. The electromagnetic coil 306 issized to fit within an un-necked pre-form article 216 such that thehelical windings 364 are disposed proximate to, but not in electricalcontact with, the walls of the pre-form article 216.

The core 370 generally increases structural integrity of theelectromagnetic coil 306 and can also be used to enhance electromagneticproperties of the electromagnetic coil 306. The core 370 can be formedfrom any suitable material, such as one or more glass, ceramic, polymerincluding resin, epoxy, elastomer, etc., combinations thereof, and thelike. Considerations for selection the core 370 material can include,for example, structural properties such as rigidity, adhesiveproperties, electrical properties such as dielectric constant andinsulating qualities, thermal conductivity, dimensional stability,shrinkage, etc. In some aspects, the core 370 is a poured polyurethaneepoxy resin such as Freeman 1090 Casting Resin, available from FreemanManufacturing And Supply Co. (Avon, Ohio). It is contemplated that thecore 370 may be rapid prototyped or 3-D printed, or machined. In someembodiments, the core 370 includes one or more passages that deliverpressurized air to the interior of the pre-form article 216. The coremay also include cooling passages providing, for example, air or liquidcooling. For example, heat pipes 1404 may be included within the core370 to carry heat away from the electromagnetic coil 306 and deliver theheat to cooling fins 1406 for dissipation (e.g., FIG. 14 ).

The insulating sleeve 372 is coupled to the electromagnetic coil 306 andis configured to inhibit flow of electrical energy form theelectromagnetic coil 306 to the multi-segment mold 308. In some aspects,the insulating sleeve 372 is used alone or in conjunction withcorresponding components to form an air-tight seal between the first end360 of the electromagnetic coil 306 and the multi-segmented mold 308.

FIGS. 7A-D illustrate a method of manufacturing the electromagnetic coil306, according to some aspects of the present disclosure. FIG. 7A showsan exploded view of the top cap 362, a winding tube 364′, the bottom cap366, the return conductor 368, and the insulating sleeve 372. Theconductive components, e.g., the top cap 362, winding tube 364′, bottomcap 366, and return conductor 368, may be assembled and attached usingany suitable fastening method such as welding, brazing, soldering,threaded connection, clipping, etc. The top cap may be smaller, largeror similar diameter to the tube.

As shown in FIG. 7B, the top cap 362, winding tube 364′, bottom cap 366,and return conductor 368 form a cavity 370′ when assembled. This cavity370′ is then filled with a suitable material such as an epoxy or othernon-conductive support filler for strength. The pourable material thensolidifies, forming the core 370. It is contemplated that the core 370may be formed by other methods, such as rapid prototyping or machining,and inserted into the electromagnetic coil 306 prior to the componentsbeing fixed together.

The winding tube 364′ is then milled or machined to form the helicalwindings 364. The milling can be used to produce a single helical coil,or multiple helical coils in parallel. In the illustrated example, thehelical windings 364 form a triple-helix pattern where there are threeparallel electrical paths between the top cap 362 and the bottom cap366. Multiple electrical paths can be used to provide differentinductance. Beneficially, the same assembly procedures and machiningequipment can be used to produce coils having markedly differentconfigurations and electrical properties without the need to change outany components used in the manufacturing process. Additionally, millingcan produce parallel helical windings more quickly, cheaply, andefficiently than typical wound-wire coils. Further, milling providesadditional cost-savings for each electromagnetic coil 306 becausegeneral equipment such as CNC machines may be used as opposed tospecialized wire-wrapping machines or wrapping each coil by hand. It iscontemplated that other methods may be used to produce helical windingssuch as wrapping wires or ribbons and electrically coupling the wires orribbons to the bottom cap 366 and top cap 362. Beneficially, the bottomcap 366 can be machined to be electrically coupled to multiple, parallelhelical windings. This provides for a parallel-path electromagnetic coil306 without the need for complicated winding patterns to return theconductors forming the windings though the center of the electromagneticcoil 306.

Beneficially, milling the helical windings 364 assists in overcomingdifficulties associated with fabricating wound-wire coils for existingsystems, particularly that wound-wire coils are often cumbersome anddifficult, if not impossible, to form in such a way that theelectromagnetic coil extends into the lower sidewall of a pre-formarticle 216. This problem is only amplified when attempting to windmultiple coils in parallel.

Milling the helical windings 364 also provides a convenient method forcontrolling magnetic domains formed along the length of theelectromagnetic coil 306. For example, the milling can quickly andeasily form multiple, parallel conductor paths to provide generallyuniform force extending radially from the electromagnetic coil 306.Additionally or alternatively, multiple magnetic domains can be formedaxially along the helix by varying properties of the helical windings364 such as helix angles and “pitch” to provide non-uniform spacing. Thepitch can be adjusted by varying the space between adjacent windings 364along the length of the electromagnetic coil 306 and the width of thehelical windings 364 along the length of the electromagnetic coil 306.

For example, the pitch can be non-uniform along the length of thehelical windings 364 so that a first portion of the helical windings 364that corresponds to a first portion of the pre-form article 216, such asthe top, may have a higher pitch (closer together) than a second portionof the helical windings 364 corresponding to a second portion of thepre-form article 216, such as the midsection. In this example, a singlepulse through the helical windings 364 will produce a greater force onthe first portion of the pre-form article 216 than the force produced onthe second portion of the pre-form article 216. These non-uniform forcescan aid in forming a shaped container, such as an hourglass-shapedcontainer.

It is contemplated that other properties of the helical windings 364such as the height, width, and shape of the cross-sectional profile canbe altered to produce multiple magnetic domains. For example, at highfrequencies, electrical current travels generally along the outer edgesof conductors. In some aspects, the exterior surface geometry is shapedto produce beneficial properties.

As shown in FIG. 7C, milling the winding tube 364′ may produce helicalwindings 364 having a generally rectangular cross section. Thecross-sectional height of the helical windings 364 generally correspondswith the thickness of the winding tube 364′, but can be reduced alongsome or all of the helical windings 364 during the milling process. Thecross-sectional width of the helical windings is selected during themilling process and may be continuous along the length of the helicalwindings 364 or may be varied.

Beneficially, the rectangular cross-sectional profile of the helicalwindings 364 and the ability to alter the cross-sectional height of thehelical windings 364 provides for a low-profile electromagnetic coil 306that can fit into narrower clearances and geometries, such as the domedbottom of pre-form articles 216, than typical wound-wire coils. Thisallows for the efficient application of magnetic flux to portions of thepre-form article 216 near the domed bottom. By removing additionalmaterial from the electromagnetic coil 306 disposed near the bottom ofthe pre-form article 216, the current path can be optimized to beeffective at the very lowest parts of the sidewall without interferingwith the domed bottom. In some aspects, the helical windings 364 extendto the transition zone of the pre-form article 216 (e.g., 25 mm from thebottom). In some aspects, the helical windings 364 extend into thetransition zone (e.g., 20 mm, 15 mm, or even 5 mm from the bottom).

After milling, the empty space between adjacent helical windings 364 canbe filled with epoxy or other material. Beneficially, this providesadditional rigidity to the helical windings 364 and inhibits movement ofthe helical windings 364 during application of the electricalpulses-particularly lateral movement. This may also extend the life ofthe electromagnetic coil 306. Additionally, the outer surface of thehelical windings 364 can be coated, wrapped, or sleeved with a materialsuch as an epoxy to provide electrical insulation, strength, or otherbeneficial properties. It is contemplated that other forming methods canbe used to achieve these configurations and beneficial properties.

As shown in FIG. 7D, grooves 374 can be machined into the wall of thehelical windings 364 to receive O-rings or other sealing devices toprovide a seal between the electromagnetic coil 306 and inner wall ofthe pre-form article 216. In one example, O-rings are inserted into thegrooves 374, and a flexible shrink-sleeve is installed over both theelectromagnetic coil 306 and the O-rings. The sleeve conforms to theshape of the electromagnetic coil 306 with the O-rings, and theresulting bulge over the O-rings provides compliant sealing against thepre-form article 216 wall. In some aspects, the sleeve does not coverthe O-rings such that the O-rings form a direct seal with the pre-formarticle 216 wall.

Referring now to FIG. 14 , an embodiment of an electromagnetic coil 306′is shown, excluding inner fill material and electrical insulation. Theelectromagnetic coil 306′ includes a winding tube 364′ having helicalwindings 364 disposed on a portion thereof, a bottom cap 366, a returnconductor 368, a core 370, and an insulating sleeve 372′. In theillustrated embodiment, the winding tube 364′ can be directly attachedto the forming modules and electrically coupled to the power sourcewithout use of a top conductor 362, which provides for fewer jointsbetween components, leading to improved electrical properties and lowermanufacturing costs. Additionally, sealing member 1402 is disposedbetween the top of the pre-form article 216 and the insulating sleeve372′ to prevent gas transfer between the pressurized-side andvacuum-side of the pre-form article 216. Beneficially, the seal isdisposed about the outer radius of the helical windings 362, whichallows for reconfigurability of the system to provide for forming ofpre-form articles 216 having different lengths. For example, shorterpre-form articles 216 can be accommodated by replacing the sealingmember 1402 with a longer sealing member 1402.

Referring again to FIGS. 2A-2B and FIGS. 3A-3B, in one example ofoperation of the electromagnetic-forming system 100, a pre-form article216 is received by a pocket 214 of the infeed starwheel 202 whilecontinually rotating. The infeed starwheel 202 then deposits thepre-form article 216 into the loading portion 301 of a respectiveforming module 208 on the forming turret 204 and is secured by theloading mechanism 302 while the forming turret 204 continually rotates.The rotation of the forming turret 204 relative to the loading cam 210causes the loading cam 210 to urge the loading-mechanism actuator 304towards the axis of rotation of the forming turret 204. This causes theloading mechanism 302 to travel from the first position to the secondposition to dispose the pre-form article 216 about the electromagneticcoil 306. The rotation of the forming turret 204 relative to the moldcam 212 causes the mold cam 212 to urge the mold actuator 310 towardsthe axis of rotation of the forming turret 204. This inward movementurges the multi-segment mold 308 to close around the pre-form article216 when the pre-form article 216 is disposed about the electromagneticcoil 306.

After the multi-segment mold 308 is closed, the volume between thepre-form article 216 and the inner surface of the multi-segment mold 308is evacuated to create a vacuum. The vacuum provides for fewer sidewallaberrations because there is less opportunity for air to become trappedbetween the sidewall of the formed container 218 and the inner surface412 of the mold inserts 406 a-c. Additionally, the vacuum allowslower-energy pulses to be used for forming because there is lessresistance against outward movement of the sidewall of the pre-formarticle 216. In some aspects, vacuum levels of less than about −25 inHg(about −12.3 psia) are used. In further aspects, vacuum levels of lessthan about −26 inHg, (about −12.8 psia) are used. In yet furtheraspects, vacuum levels of less than about −27 inHg (about −13.3 psia)are used. In still yet further aspects, vacuum levels of less than about−28 inHg (about −13.8 psia) are used.

While evacuating the volume between the pre-form article 216 and theinner surface of the multi-segment mold 308 assists in reducing sidewallaberrations due to trapped air, it has been determined that aberrationssuch as wrinkling may also be produced by “ricochet” or “bounce” of thesidewalls of the pre-form article 216 during the electromagneticforming. Ricochet is generally caused by the sidewall of pre-formarticles 216 expanding with such speed that the impact between thesidewall and the mold causes the sidewall to bounce off of the innersurface 412 of the mold inserts 406 a-c, and retract toward theelectromagnetic coil 306 before coming to rest. It is contemplatedmodifying the elasticity or resiliency of the mold inserts 406 a-c mayalter the amount of ricochet.

Surprisingly, the problem of ricochet is generally more difficult toovercome in smooth-walled articles than embossed articles. It isbelieved that the embossing inhibits ricochet by providing addedrigidity to the formed container 218, dissipating kinetic energy informing the ridges, and increasing the duration of the forming of thesidewall and, thus, lessening the impulse on the sidewall duringforming. Moreover, the problem of ricochet is also generally moredifficult to overcome in straight-walled articles than in articleshaving tapered sides, such as those having an “hourglass” or othercontoured shape.

Contemporaneously with the application of a vacuum, the volume betweenthe pre-form article 216 and the outer surface of the electromagneticcoil 306 may be pressurized. The pressurized interior volume of thepre-form article 216 allows for lower-energy pulses to be used to formthe container. Beneficially, the pressurized interior volume of thepre-form article 216 helps to counteract ricochet of the wall off of theinner surface of the mold. In some aspects, pressurized air is forcedthrough the channel 704 (FIG. 7D) in the inner conductor 368 and ispassed to the inner sidewall of pre-form article 216 through passages702 in the shaped bottom cap 366. Surprisingly, pressures of greaterthan about 114.7 psia can be used to produce consistent forming ofcontainers, including smooth-walled containers. In some aspects, thepressure applied is approximately at the “yield point” or “hoop stress”of the pre-form article 216. That is, the pressure applied will causethe pre-form article 216 to stretch slightly, but generally will notsubstantially or permanently deform the pre-form article 216. Thus,pre-form articles 216 with thinner walls will require less pressure thanpre-form articles 216 with thicker walls. For example, it has beendiscovered that pressures between about 144.7 psia and about 184.7 psiaproduce desirable results without wrinkles for containers having anabout 2.08″ (about 5.28 cm) diameter with an about 0.009″ (about 0.023cm) wall thicknesses. In some aspects, the system 100 includes a boosterpump to receive the house-supplied pressure (typically about 104.7 psiaor less) and increase the house-supplied pressure to the desired level.It is contemplated that lower pressures may be used. More particularly,pre-form articles having thin walls (e.g., 0.007″ or 0.005″), softmaterials, or soft tempers will generally require lower pressures than144.7 psia

In accord with certain aspects described herein, a single expansion stepof annealed pre-form articles 216 can produce generally straight-walled,cylindrical formed containers 218 with diameters that have been expandedmore than about 15%. In further aspects, the single-step expansion isgreater than about 20%. In yet further aspects, the single-stepexpansion is greater than about 25%. Beneficially, expansions of greaterthan about 25% allow use of straight-wall, un-necked pre-form articles216 because features such as necks and flanges can be produced duringthe electromagnetic forming. Further in accord with aspects describedherein, a single expansion step of non-annealed pre-form articles 216can produce straight-walled, cylindrical formed containers 218 withdiameters that have been expanded up to about 12%. It is believed thatdifferent materials and different alloys can achieve still higher levelsof expansion. It is believed that air pressures in excess of about 114.7psia are needed to achieve such large single-step expansions of pre-formarticles 216 having 0.009″ thick sidewall. Other air pressures may beused depending on wall thickness and material of the pre-form article216.

After the system achieves a desired vacuum on the outside of thepre-form article 216 and a desired pressure on the inside of thepre-form article 216, one or more electromagnetic pulses are passedthrough the electromagnetic coil 306. Each electromagnetic pulse inducesa current in the pre-form article 216 that forces the pre-form article216 outward and into contact with the inner surface of the multi-segmentmold 308. In aspects applying more than one electromagnetic pulse, theproperties of each pulse may be uniform or may be varied to achievedesirable results. For example, electromagnetic pulses applied duringthe forming may have different pulse voltages, pulse duration, timebetween adjacent pulses, pulse waveforms, etc., combinations thereof,and the like. In some non-limiting examples, a 53 mm×185 mm pre-formarticle 216 with a 0.009″ wall thickness can be expanded by 25% usingabout 3 to about 4.5 KJ of energy. The amount of energy varies dependingon the desired formed container 218 geometry. The energy is transferredhas a high frequency, which is needed for forming thin metals. Thecurrent oscillates within the system until the voltage is insufficientto travel through the circuit. This occurs, for example, in the order ofmilliseconds or less. Beneficially, the pressure differential on thepre-form article and the applied energy may be independently adjusted toproduce desired characteristics and features of the formed container218. For example, for certain forming operations, lower pressuredifferential, higher energy forming will produce more desirable resultsthan higher pressure differential, lower energy forming. Conversely, forcertain other forming operations, higher pressure differential, lowerenergy forming will produce more desirable results than lower pressuredifferential, higher energy forming.

After the article is formed, the vacuum and pressurization are releasedand the system returns to atmospheric pressure. The rotation of theforming turret 204 relative to the mold cam 212 causes the mold cam 212to allow the mold actuator 310 to travel away from the axis of rotationof the forming turret 204. This outward movement urges the multi-segmentmold 308 open and releases the formed container 218 from themulti-segment mold 308. The loading cam 210 begins to disengage theloading-mechanism actuator 304, and the loading-mechanism actuator 304travels away from the center of the axis of rotation of the formingturret 204. This causes the loading mechanism 302 to travel from thesecond position to the first position to remove the formed container 218from about the electromagnetic coil 306. The outfeed starwheel 206 thenreceives the formed container 218 from the forming turret 204 and passesthe formed container 218 downstream for further processing or packaging.

Referring now to FIG. 8 , a diagram illustrating a process timingschematic for an example rotary-turret system 106 having an infeedstarwheel 202, a forming turret 204, and an outfeed starwheel 206 isshown. While the process timing schematic illustrates a plurality ofarticles disposed at various stages of forming, it should be understoodthat the following embodiment will be described with respect to a singlearticle passing through the rotary-turret system 106.

The infeed starwheel 202 receives a pre-form article 216 whilecontinually rotating. The infeed starwheel 202 then rotates in adirection D1 to deposit the pre-form article 216 in a respective formingmodule 208 of the forming turret 204. The forming turret 204 receivesthe pre-form article 216 while continually rotating in a direction D2that is opposite the infeed starwheel direction D1. For ease ofdescription, the point at which the pre-form article 216 is received bythe forming turret 204 will be referred to as the reference point or 0°.

The pre-form article 216 is transferred from the infeed starwheel 202 tothe rotary turret 206 between about 0° and about 5° of rotation at step802. After the forming module 208 receives the pre-form article 216, thepre-form article 216 is loaded onto the electromagnetic coil 306 by, forexample, the loading mechanism 302 at step 804. The loading step 804occurs between about 5° and about 50° of rotation. While the pre-formarticle 216 is being loaded onto the electromagnetic coil 306, themulti-segment mold 308 begins to close at step 806. The multi-segmentmold 308 closing occurs between about 30° and about 75° of rotation. Inthe illustrated embodiment, there is some overlap between thepre-form-loading step 804 and the mold-closing step 806 to reduce totalprocess time because the mold can be partially closed withoutinterfering with the loading step 804. Beneficially, completion of theloading step 804 prior to completion of the mold-closing step 806provides for increased longevity of sealing members such as O-rings thatare disposed between the loading mechanism 302 and the multi-segmentmold 308. Longevity is increased because the multi-segment mold 308contacts the O-rings and moves substantially inward to form the seal,producing a generally compressing force, rather than the O-rings slidinglaterally relative to the multi-segment mold 308, which would produce agenerally shearing force. After the mold-sealing step 806, a vacuum isapplied and air occupying the volume between the pre-form article 216and the inner surface of the mold 308 is evacuated at step 808. Thevacuuming step 808 occurs between about 75° and about 240° of rotation.A volume between the electromagnetic coil 306 and the pre-form article216 is pressurized at step 810. In the illustrated embodiment, thepressurizing step 810 is performed simultaneously with the vacuumingstep 808, e.g., between about 75° and about 240° of rotation. In someembodiments, the vacuuming step 808 and the pressurizing step 810 beginand/or end at different angles of rotation.

At step 812 a, the pressure of the volume between the electromagneticcoil 306 and the pre-form article 216 and the vacuum of the volumebetween the pre-form article 216 and the inner surface of the mold 308are tested and verified at about 180° of rotation. If the pressure andvacuum are verified to be within predetermined operating ranges, a firstelectromagnetic pulse is applied to the pre-form article 216 at step 814a. The first-pulse step 814 a occurs at about 195° of rotation.

A determination that the pressure and vacuum are outside of thepredetermined operating ranges could indicate one or more possiblebreaches/defects in the pre-form article 216, the multi-segment mold308, and/or other components in the system 100. For example, if thepre-form article 216 has a breach, the pressurized volume and theevacuated volume will not be separated by an air-tight seal and, thus,the pressure will be lower or closer to atmospheric pressure thanexpected. Such a breach may be dangerous if an electromagnetic pulse isapplied because the split may cause arcing, vaporization of the pre-formmaterial, and/or even explosions within the multi-segment mold 308.Thus, if the pressure and vacuum are outside of the predeterminedoperating ranges, the first-pulse step 814 a and any subsequent pulsesteps are inhibited.

After the first-pulse step 814 a, the pressure and vacuum are optionallytested again and verified at step 812 b, at about 210° of rotation. Ifthe pressure and vacuum are verified to be within predeterminedoperating ranges, a second electromagnetic pulse is applied to thepre-form article 216 at step 814 b. The second-pulse step 814 b occursat about 225° of rotation. Similarly, if the pressure and vacuum areoutside of the predetermined ranges, the second-pulse step 814 b and anysubsequent pulse steps are inhibited.

Beneficially, a verifying step such as step 812 b after anelectromagnetic pulse can also be used to determine whether the formedcontainer 218 contains structural defects such as a breach. A defectiveformed container can then be separated from the non-defective formedcontainers 218 without further testing. Additionally, the verifyingsteps 812 a,b can be used to alert operators to an issue with therotary-turret system 106 such as a defective multi-segment mold 308,electromagnetic coil 306, spark-gap mechanism, loading mechanism 302,combinations thereof, or the like. For example, adequate pressure butinadequate vacuum in a multi-segment mold 308 through two rotationscould indicate a defective multi-segment mold 308. In another example,inadequate pressure or vacuum for consecutive articles in adjacentforming modules could indicate a defective compressed-gas system 110 orvacuum system 108, respectively.

After the forming, the vacuum and pressure are released. Themulti-segment mold 308 is then opened at step 816. The mold-opening step816 occurs between about 240° and about 285° of rotation. While themulti-segment mold 308 is being opened, the loading mechanism 302 beginsto remove the formed container 218 from the electromagnetic coil 306 atstep 818. The removing step 818 occurs between about 265° and about 310°of rotation. After being removed from the electromagnetic coil 306, theformed container 218 is transferred from the rotary turret 206 to theoutfeed starwheel 208 between about 310° and about 315° of rotation atstep 820.

In some aspects, the working angle of the rotary turret 206 is about315° of rotation, and switching on and off of the components in theprocess occurs through about 330° of rotation. For consistency, thepoint at which the pre-form article 216 is received by the formingturret 204 will be referred to as the reference point or 0°.

The pre-form article 216 is loaded onto the electromagnetic coil 306 by,for example, the loading mechanism 302 between about −7.5° and about42.5° of rotation. After the pre-form loading step has been initiated,vacuum is applied to the loading mechanism 302 to assist in releasablysecuring the pre-form article 216 to the loading mechanism 302 beginningat about −4.5° and lasting until about 247.5° of rotation. After thesesteps have been initiated, the preform article 216 is transferred fromthe infeed starwheel 202 to the rotary turret 206 at about 0° ofrotation. While the pre-form article 216 is being loaded onto theelectromagnetic coil 306, the multi-segment mold 308 begins to close.The multi-segment mold 308 closing occurs between about 22.5° and about67.5° of rotation. As stated above, there is some overlap between thepre-form loading step and the mold-closing step to reduce total processtime, and the pre-form loading step is completed prior to completion ofthe mold-closing step to provide increased longevity of sealing membersdisposed between the loading mechanism 302 and the multi-segment mold308. After the mold-sealing step, a vacuum is applied to the moldmulti-segment mold 308 from about 67.5° to about 247.5° of rotation, andair occupying the volume between the pre-form article 216 and the innersurface of the mold 308 is evacuated. A volume between theelectromagnetic coil 306 and the pre-form article 216 is pressurizedbetween about 187.5 and 247.5°.

While pressure is being applied to the pre-form article 216 and vacuumis being applied to the multi-segment mold 308, forming steps areperformed. Preferably, the forming step includes at least one leak testand at least one forming pulse. Leak tests are performed to verify thepressure and vacuum levels. If the pressure and vacuum are withinpredetermined range, one or more pulses are applied. If the pressure andvacuum are outside of the predetermined operating ranges, any subsequentpulses are inhibited. Preferably, a leak test is performed prior to eachapplied pulse. It is contemplated that a pulse may be applied prior toany leak test.

After the forming steps, the vacuum and pressure are released and themulti-segment mold 308 is opened between about 262.5° and 292.5° ofrotation. While the multi-segment mold 308 is being opened, theunloading step is performed between about 272.5° and 322.5° of rotationto remove the formed container 218 from the electromagnetic coil 306 andposition the formed article 218 to be transferred from the rotary turret206 to the outfeed starwheel 208. Vacuum is applied to the loadingmechanism 308 between about 262.5° and 312.5° of rotation to releasablysecure the formed article 218. The formed article 218 is transferredfrom the rotary turret 206 to the outfeed starwheel 208 at about 315° ofrotation.

While the working angles described in the above embodiments are about315°, it is contemplated that greater or smaller working angles may beused, such as about 180°, about 270°, about 330°, about 345°, or thelike. Further, it is contemplated that the angular ranges or proportionsof the working angle occupied by each step may vary. Additionally,overlaps between adjacent steps may also be added, varied, or removed.

Referring now to FIG. 9 , an electrical schematic of an exemplaryforming system 900 is shown. The forming system 900 includes ahigh-voltage power supply 902, an emergency-stop circuit 904, adischarge circuit 906, a capacitor bank 908, a forming circuit 910 andground. The emergency-stop circuit 904, discharge circuit 906, capacitorbank 908, and forming circuit 910 are electrically coupled in parallel.The high-voltage power supply 902 passes high-voltage current throughthe system to charge the capacitors 918. The emergency-stop circuit 904provides a quick discharge circuit 904 that can be actuated to safelydischarge the capacitor bank 908 in an emergency situation. Theemergency-stop circuit 904 includes a resistor 912 and a quick-dischargehigh-voltage chip resistor 913.

The discharge circuit 906 is configured to slowly drain energy from thecapacitor bank 908 when the power supply 902 is not supplying power tothe system 900. The discharge circuit 906 includes a plurality ofresistors 912 that provide a closed circuit that slowly drains thecapacitors 918 when the system is powered down, inhibiting unintentionaldischarge of the capacitors 918.

The capacitor bank 908 includes a plurality of capacitors 918 configuredto store energy to be supplied to the electromagnetic coil 306. Thisenergy is supplied to the electromagnetic coil 306 in short impulse,high-voltage bursts.

The forming circuit 910 includes a discharge-control mechanism 916configured to selectively actuate discharge of the capacitor bank 908 tothe electromagnetic coil 306. The discharge-control mechanism 916 can beany suitable high-current switching device such as a Paschen-modespark-gap switch, various spark gaps, rail gaps, trigatron, ignitrons,high-current solid-state switches, combinations thereof, and the like.

The energy (E_(c)) discharged per pre-form article 216 is given by theformula E_(c)=½C·V_(c) ², where C is the capacitance of the capacitorbank 908 and V_(c) is the voltage supplied by the capacitors. In somenon-limiting aspects, the capacitor bank 908 includes four capacitors918 coupled in parallel, and each capacitor 918 has about 6 μF ofcapacitance. The voltage supplied during the discharge is about 18,000V. Thus, the energy discharged per pre-form article 216 is about 3888 J.

The total power needed for a high-speed continuous system is given bythe formula Power=CPM·E_(c), where CPM is the number of cans per minuteand E_(c) is the energy discharged per pre-form article 216. Thus, ifthe energy discharged per pre-form article 216 is about 3888 J, thepower needed is about 65 W for one can per minute, about 1944 W forthirty cans per minute, about 7776 W for 120 cans per minute, and 2×10⁵W for 2400 cans per minute.

The amperage needed to supply a high-speed continuous system is given bythe formula A_(c)=Power/V_(c) where power is the total power needed andV_(c) is the capacitor voltage. In the above-described example, about0.0036 A are needed for one can per minute, about 0.108 A is needed forthirty cans per minute, about 0.432 A is needed for 120 cans per minute,and 8.64 A is needed for 2400 cans per minute. It is noted that thesecalculations relate to the power needed to supply electromagnetic pulsesand do not include other aspects of the system such as the powerrequired by drive motors, vacuum systems, compressed-gas systems,controls, etc.

It is believed that high-voltage, low capacitance, and low inductancesystem allows for improved and surprising success of electromagneticforming systems in accord with aspects of the present invention. At thesame energy and inductance, a system with high voltage, low capacitance,and low inductance will resonate at a higher frequency than a systemwith low voltage, high capacitance, and low inductance system. It isbelieved that the resulting high-frequency pulse provides beneficialforming properties by producing greater eddy currents in verythin-walled pre-form articles 216 than those produced by lower-voltage,higher-capacitance circuits of equal inductance and energy. These eddycurrents provide the electromagnetic force that opposes theelectromagnetic force from the coil, which provides for more efficientforming.

Referring back to FIG. 1 , the discharge-control mechanism 104 isconfigured to selectively actuate discharge of the capacitors to therotary-turret system 106. A selected electromagnetic pulse may bedelivered to one or more forming modules 208 simultaneously.

In some aspects, the discharge-control mechanism 104 includes aspark-gap mechanism to pass current from the capacitor bank to theelectromagnetic coil 306. The spark-gap mechanism includes a firstelectrode and a second electrode spaced a predetermined distance apart.The predetermined distance is selected such that electricity is passedfrom the first electrode to the second electrode when theelectric-potential difference between the two electrodes reaches adesired level. Additionally, the spark-gap mechanism can be placed in ahousing that allows for dynamically altering the atmosphere within thehousing. For example, a vacuum can be applied to the spark-gap mechanismto lower resistance between the electrodes and, thus, control dischargeof the capacitors. Pressure can be applied to the mechanism to inhibitthe spark. The open spark causes some material to be ablated from eachof the electrodes and, thus, requires replacement of both electrodesafter a period of use.

In some aspects, a moving spark-gap mechanism is used to pass currentfrom the capacitor bank to the electromagnetic coil 306. The movingspark-gap includes a pair of stationary electrodes and a plurality ofmovable electrode pairs. As will be described with respect to FIG. 10Abelow, the return path can be formed using a pair of stationaryelectrodes, or may be formed using, a single stationary electrode with aslip-ring for the return path. The stationary electrodes areelectrically coupled to the charging circuit 102 and each of the movingelectrode pairs are electrically coupled to one or more forming modules208. In operation, each pair of moving electrodes is passed in proximityto the stationary electrodes. This allows current to flow from thestationary electrodes to the proximate movable electrode pair, similarto a “distributor” used in the automotive industry. In some aspects,each forming module 208 includes a moving electrode pair disposedthereon. The stationary electrodes are disposed external to the formingturret 204 such that current passes from the stationary electrodes to arespective moving electrode pair when the respective moving electrodepair is less than a predetermined distance away from the stationaryelectrodes. The predetermined distance is selected based on factors suchas voltage to be delivered, pulse duration, pulse shape, combinationsthereof, and the like. Beneficially, the moving spark-gap mechanismallows for the oftentimes large, bulky capacitors and most of thecontrols to remain stationary while the forming turret 204 continuallyspins. Beneficially, the moving spark-gap mechanism provides benefits oflowering overall cost of a spark-gap mechanism. That is, the stationaryelectrode reduces the number of electrodes in the system by about halfas compared to a traditional spark-gap mechanism. Thus, these electrodescan be comprised of a generally higher-cost, heavy-duty material thatsignificantly resists ablation without a substantial cost increase tothe system. Further, an added benefit of the moving spark-gap mechanismis a lower cost of maintenance. Further still, by reducing the number ofelectrodes needed, the stationary electrodes can include anautomatic-adjustment mechanism that is configured to automaticallycompensate for the ablation of material.

Referring now to FIG. 10A, a schematic of a system 1000 including acharging circuit 102 and a rotary-turret system 106 with a movingspark-gap mechanism 1002 disposed therebetween is shown according toaspects of the present disclosure. The moving spark-gap mechanism 1002includes two stationary electrodes 1004 and a plurality of movingelectrode pairs 1006. The charging circuit 102 includes a power source1020 such as a high-voltage power supply, a capacitor bank 1022, aground 1024, and stationary electrodes 1004. The stationary electrodes1004 are spaced a sufficient distance apart to inhibit arcingtherebetween, thus inhibiting short circuits. The capacitor bank 1022 isdisposed between the power source 1020 and the ground 1024 to allow thecapacitors to charge when the spark gap is open. Each of the pluralityof moving electrode pairs 1006 are electrically coupled to a respectiveelectromagnetic coil 306. When the moving electrode pairs 1006 come intoproximity with the stationary electrodes 1004, the high-voltage currentarcs across the gaps and the circuit closes. The arrangement of themoving spark-gap mechanism 1002 in parallel with the capacitor bank 1022allows the capacitor bank 1022 to discharge its energy into theelectromagnetic coil 306. It is contemplated that each electromagneticcoil 306 may be coupled to an independent ground and, thus, include onlya single moving electrode corresponding to a single stationaryelectrode.

In some aspects, a moving inductive-coil mechanism is used to passcurrent from the capacitor bank to the electromagnetic coil 306. Themoving inductive-coil mechanism includes one or more stationary coilsand a plurality of moving coils. The stationary coil(s) are electricallycoupled to the charging circuit 102. Each of the plurality of movingcoils is electrically coupled to one or more of the forming modules 208.For example, each moving coil is associated with a respective formingcoil. In operation, each of the moving coils is passed in proximity tothe one or more stationary coils. When the stationary coil and arespective moving coil are disposed within close proximity, thestationary coil induces a current in the moving coil toelectromagnetically transfer energy from the capacitor bank. Thisinduced current avoids forming a spark between electrodes, thusassisting in preventing ablation and lowering overall maintenance costsfor the system. Beneficially, current to the stationary coil can beswitched by, for example, solid state switches or spark gaps that arelocated remotely from the process turret.

Referring now to FIG. JOB, a schematic of a system 1001 including acharging circuit 102 and a rotary-turret system 106 with a movinginductive-coil mechanism 1042 disposed therebetween is shown, accordingto aspects of the present disclosure. The moving inductive-coilmechanism 1042 includes a stationary coil 1044 and a plurality of movingcoils 1046. The charging circuit 102 includes a power source 1020, acapacitor bank 1022, a ground 1024, the stationary coil 1044, and acontrol mechanism 1026. The control mechanism 1026 selectively activatescurrent flow through the stationary coil 1044 and can be any suitablehigh-current switching device such as a Paschen-mode spark-gap switch,various spark gaps, rail gaps, trigatron, ignitrons, high-currentsolid-state switches, and the like. The capacitor bank 1022 is disposedbetween the power source 1020 and the ground 1024 to allow thecapacitors to charge when the control mechanism 1026 is open, or in theOFF state. Each of the plurality of moving coils 1046 is electricallycoupled to the electromagnetic coil 306 such that an induced current ina moving coil 1046 produces an induced current in the respectiveelectromagnetic coil 306. When the stationary coil 1044 is in proximityto a respective moving coil 1046, the control mechanism 1026 is actuatedto the ON state, and the capacitor bank 1022 discharges through thestationary coil 1044. This discharge induces a current in a respectiveone of the plurality of moving coils 1046, which is transferred to theelectromagnetic coil 306. Beneficially, the number of windings on eachof the plurality of moving coils 1046 can be increased relative to thenumber of windings on the stationary coil 1044 and to produce beneficialforming properties through use of higher voltage pulses.

In some aspects, one or more slip rings are used to pass current fromthe capacitor bank to the electromagnetic coil 306. The slip ringincludes one or more brushes to transfer energy from the stationaryportion to the rotating portion. For example, each of the brushes can beelectrically coupled to one or more forming modules 208. During aportion of the travel of the forming turret 204, the respective brushcontacts the stationary portion of the slip ring and transfers energyfrom the capacitor bank to the respective forming modules 208.Alternatively, the brush may be stationary and may contact movingportions of the slip ring to transfer energy from the capacitor bank tothe respective forming modules 208.

In some aspects, the capacitor bank is included on the forming turret204 and rotates therewith. The current can then be passed from thecapacitor bank to the electromagnetic coil 306 using, for example, solidstate switches or spark-gap mechanisms. Beneficially, lower-currentelectricity may be passed through slip rings to charge the capacitors,and the high-current pulse may be completely contained on the processturret. Beneficially, including the capacitor bank with the rotaryturret 204 provides for a more self-contained electromagnetic formingapparatus.

Multiple capacitor banks may be included within the charging circuit102, and power supplied to the forming modules 208 may be alternatedbetween the capacitor banks. Such a configuration may be used to providefor the forming turret 204 to rotate at a faster rate than systems witha single capacitor bank. In an example, a single stationary electrode isused and the power supplied to the single electrode is alternatedbetween the first and second capacitor bank. In another example, twostationary electrodes can be used with each stationary electrode beingcoupled to one of the capacitor banks and engaging a respectiveplurality of moving electrodes. In this configuration, the movingelectrodes of adjacent forming modules 208 alternate between the firstplurality of moving electrodes and the second plurality of movingelectrodes (e.g., modules 1,3,5, etc. would have moving electrodes fromthe first plurality of moving electrodes and modules 2,4,6, etc. wouldhave moving electrodes from the second plurality of moving electrodes).

In some aspects, multiple electromagnetic pulses used within the sameforming cycle can assist in improving the forming detail of theresulting container. Multiple electromagnetic pulses such as double- ortriple-pulse systems and methods can be used to achieve improved featuredefinition and smoothness. Beneficially, multiple pulses can be used toconsistently produce straight-walled formed containers 216.Surprisingly, these containers are more difficult to produce than shapedor embossed containers. Such a container can be consistently producedusing, for example, a two-pulse process. The two-pulse process mayinclude a first, lower-energy pulse to expand the mid-section to theinner surface 412 of the multi-segment mold 308. In some aspects, theupper and lower ends of the pre-form article 216 expand as well, butgenerally do not contact the inner surface 412 of the mold, or docontact the inner surface 412 of the mold, but lack adequate featuredefinition. A higher-energy second pulse is then used to further expandthe upper and lower portions of the pre-form article 216 to expand intocontact with the inner surface 412 of the multi-segment mold 308. Forexample, in some aspects, a first pulse having 16,600V and a secondpulse having 18,000V is used to consistently form straight-walled formedcontainers 216. Two-pulse processes are generally less likely to causethe mid-section wall to “bounce” because the mid-section wall does nothave enough distance between it and the inner surface 412 to accelerateto a velocity that would cause ricochet or bounce back. Beneficially,these subsequent pulses can also further improve features such asembossing detail by more-gently urging the sidewall of the formedcontainer 218 outward into the mold, thus better conforming to the moldstructure without generally causing aberrations. Even more beneficially,multiple pulses can be used to reduce the vacuum level required toconsistently form articles without significant aberrations. By partiallyforming the pre-form article 216 with a lower-energy first pulse, airbetween the wall of the pre-form article 216 and the inner surface 412of the multi-segment mold 308 is inhibited from becoming highlycompressed in small pockets. The remaining voids between the wall of thearticle and the inner surface 412 of the multi-segment mold 308. Thisprovides less movement and less volume change during subsequent pulses,which also lessens the need for high vacuum.

In some aspects, a portion of the formed container 218 (e.g., themid-section) is expanded less than the remaining portions of the formedcontainer 218 (e.g., the upper and lower ends) to produce a formedcontainer 218 having a generally hourglass shape. Such a container canbe consistently produced using, for example, a two-pulse process. Insome aspects, first pulse causes the upper and lower ends of thepre-form article 216 expand as well, but generally do not contact theinner surface 412 of the mold. The higher-energy second pulse is thenused to further expand the upper and lower portions of the pre-formarticle 216 to into contact with the inner surface 412 of themulti-segment mold 308.

In some aspects where multiple stationary electrodes share the samecapacitor bank, the stationary electrodes can be disposed such that thetiming between pulses assists in determining the amount of currentdelivered from the capacitor bank. That is, by selecting the timing suchthat the capacitor bank does not charge to its full capability, alower-energy pulse will be applied. Additionally or alternatively, thetwo stationary electrodes can each be electrically coupled to arespective capacitor bank, where each capacitor bank is configured todeliver a different level of energy.

According to aspects of the present disclosure, a variable-speedstarwheel may be configured to receive articles such as pre-formarticles 216 or formed containers 218 that are traveling at a firstspeed, then accelerate or decelerate the articles to be deposited at asecond speed. In some aspects, the change in speed is accomplished, forexample, by altering the distance of the pockets 214 from an axis ofrotation 1108 between receiving and depositing the articles, delaying orretarding the position of the pockets 214 relative to rotation of adriving mechanism 1102, combinations thereof, or the like.

Referring now to FIGS. 11A-C, a variable-speed starwheel 1100 is shownaccording to aspects of the present disclosure. In non-limitingexamples, the variable-speed starwheel 1100 includes a driving mechanism1102, a cam surface 1104, and a plurality of arms 1106. The drivingmechanism 1102 is configured to rotate about an axis of rotation 1108and drives the variable-speed starwheel 1100. The driving mechanism 1102can be, for example, a hub coupled to a synchronization mechanism thatreceives drive-power from another module in the system, or can be anindependently driven motor.

The cam surface 1104 generally does not rotate about the axis ofrotation 1108 and defines an irregular shape with variable radialdistance from the axis of rotation 1108. The variable radial distanceincludes a first radial distance R1 disposed at a first angular positionand a second radial distance R2 at a second angular position.

Each of the plurality of arms 1106 includes a pocket 214, a pivotmechanism 1160, and a cam follower 1162. The pockets 214 are configuredto releasably receive the articles. Each pivot mechanism 1160 is spaceda distance from the pocket 214. The pivot mechanisms 1160 are attachedto the driving mechanism 1102 and are disposed a fixed distance awayfrom the axis of rotation 1108. Each arm 1106 swivels about each pivotmechanism 1160 such that an angle between a first line extending fromthe axis of rotation 1108 to the pivot mechanism 1160 and a second lineextending from the pivot mechanism 1160 to the pocket 214 can be varied.

The cam follower 1162 is configured to engage the cam surface 1104. Thecam follower 1162 is offset from the pivot mechanism 1160 such that thearm 1106 is advanced or retarded as the cam follower 1162 rises andfalls. The advancing or retarding of the arm is used to increase ordecrease the circumferential velocity and the pitch of the arm 1106. Insome aspects, the arm 1106 may be biased such that the cam follower 1162is urged into engagement with the cam surface 1104. In some aspects, thecam follower 1162 may be disposed within a slotted cam or grooved camthat includes a first cam surface 1104 to urge the cam follower 1162 ina first direction (e.g., outward) and a second cam surface 1104 to urgethe cam follower 1162 in a second direction (e.g., inward). Engagementof the cam follower 1162 with the cam surface 1104 may be used tocontrol the angle of the arm 1106. Beneficially, the arms can be“nested” to provide for greater numbers of arms about the variable-speedstarwheel 1100. In the illustrated embodiment, the cam follower 1162 isaxially offset from the pivot mechanism 1160 and pocket 214 such thatthe cam follower 1162 of a first arm 1106 overlaps with a second arm1106 when viewed in an axial direction. It is contemplated that othernesting configurations can be used.

As shown, a first pocket 214 a disposed at a first angular positionextends a first distance D1 away from the axis of rotation 1108. Thepoint of engagement between the first cam follower 1162 a and the camsurface 1104 is the first radial distance R1 from the axis of rotation1108. The first arm 1106 a is disposed in a generally straight line(e.g., the angle may be about 180°) such that the first distance D1 isthe farthest distance from the axis of rotation 1108. A second pocket214 b disposed at a second angular position extends a second distance D2away from the axis of rotation 1108. The point of engagement between thecam follower 1162 b and the cam surface 1104 is a second radial distanceR2 from the axis of rotation 1108. The arm 1106 is disposed at anoblique angle (e.g., the angle may be about 120°) such that the seconddistance D2 is a shorter distance from the axis of rotation 1108 thanthe first distance D1. Because the angular velocity of thevariable-speed starwheel 1100 is generally constant, the linear velocityof the first pocket 214 a is greater than the linear velocity of thesecond pocket 214 b.

Moreover, pivotable movement of the arms 1106 relative to the drivingmechanism 1102 retards or advances the pocket 214 relative to thedriving mechanism 1102. The rate that the pocket 214 advances or retardsdepends on the rate of change of the radius of the cam surface 1104relative to the position of the pivot mechanism 1160. Beneficially,large changes in the linear velocity of the pocket 214 can be achievedwithout large changes between the first distance D1 and the seconddistance D2.

Referring now to FIGS. 11D-E, a variable-speed starwheel 1100′ is shownaccording to aspects of the present disclosure. In some aspects, thevariable-speed starwheel 1100′ includes a driving mechanism 1102, a camsurface 1104, and a plurality of arms 1106′. Each of the plurality ofarms 1106′ includes a pocket 214 and a sliding mechanism that moves thepocket 214 inwardly or outwardly from the axis of rotation 1108. In someaspects, the sliding mechanism is a telescoping arm. The telescoping armincludes a first portion 1122 a that is attached to the drivingmechanism 1102 and a second portion 1122 b that is attached to thepocket 214. In some aspects, the pocket 214 is urged inwardly oroutwardly by engagement of a cam follower 1162 with a cam surface 1104.The cam follower 1162 may be mounted, for example, on the second portion1122 b of the telescoping arm. In some aspects, the pocket 214 is urgedinward or outward by a hydraulic cylinder.

In the illustrated example, the cam surfaces 1104 form a generallycircular shape that is disposed eccentrically about the axis of rotation1108, providing a variable radius that depends on angular position ofthe arms 1106′. In the illustrated example, the radius between the camsurface 1104 and the axis of rotation 1108 is directly related to thedistance between the pocket 214 and the axis of rotation 1108. Becausethe angular velocity of the variable-speed starwheel 1100′ is generallyconstant, the linear velocity of pockets 214 a greater distance from theaxis of rotation 1108 is greater than the linear velocity of pockets 214a lesser distance from the axis of rotation. It is contemplated thatnon-circular cam surfaces 1104 can be used.

Referring now to FIGS. 11F-G, a variable-speed starwheel 1100″ is shownaccording to aspects of the present disclosure. In some aspects, thevariable-speed starwheel 1100″ includes a driving mechanism 1102, afirst cam surface 1104 a, a second cam surface 1104 b, and a pluralityof arms 1106′.

The first cam surface 1104 a generally does not rotate about the axis ofrotation 1108 and defines a shape with a variable radial distance fromthe axis of rotation 1108. The first cam surface 1104 a may define agenerally circular shape disposed eccentrically from the axis ofrotation 1108 as shown, may define an irregular shape, or the like.

The second cam surface 1104 b generally does not rotate about the axisof rotation 1108 and defines a shape with a variable radial distancefrom the axis of rotation 1108. The second cam surface 1104 b may definean irregular shape as shown, may define a generally circular shapedisposed eccentrically from the axis of rotation 1108, or the like.

Each of the plurality of arms 1106″ includes a pocket 214, a first pivotmechanism 1160 a, a second pivot mechanism 1160 b, a first cam follower1162 a, and a second cam follower 1162 b. The first pivot mechanism 1160is attached to the driving mechanism 1102 and disposed a fixed distancefrom the axis of rotation 1108. The arm 1106″ swivels about the firstpivot mechanism 1160 a such that the arm 1106″ is advanced or retardedrelative to rotation of the driving mechanism 1102.

The first cam follower 1162 a is configured to engage the first camsurface 1104 a. The first cam follower 1162 a is offset from the firstpivot mechanism 1160 a such that the arm 1106″ is advanced or retardedas the first cam follower 1162 a rises and falls. The advancing orretarding of the arm 1162″ is generally responsible for increasing ordecreasing the circumferential velocity and the pitch of the arm 1106″.

The second pivot mechanism 1160 b is disposed a distance from the firstpivot mechanism 1160 a and separates the arm 1106″ into a first portion1122 a and a second portion 1122 b. The second pivot mechanism 1160 ballows the first portion 1122 a to pivot relative to the second portion1122 b. The pivotable movement of the first portion 1122 a relative tothe second portion 1122 b provides for rotational or “rolling” movementof the pocket 214, and provides for adjusting the distance between thepocket 214 and the axis of rotation 1108.

The second cam follower 1162 b is configured to engage the second camsurface 1104 b. The second cam follower 1162 b is offset from the secondpivot mechanism 1160 b such that an angle between the first portion 1122a and the second portion 1122 b of the arm 1162″ is increased ordecreased as the second cam follower 1162 b rises or falls. Theincreasing or decreasing of the angle between the first portion 1122 aand the second portion 1122 b is generally responsible for increasing ordecreasing the distance between the pocket 214 and the axis of rotation1108.

Beneficially, the two degrees of freedom for the variable-speedstarwheel 1106″ provide for more desirable transfer between thevariable-speed starwheel 1100″ and an adjacent unit such as the formingturret 204. The compound adjustment of the pocket 214 can be used tomore closely track both linear speed of the adjacent unit and a radialpath centered on the axis of rotation the adjacent unit. This allows thetransfer to occur along a path rather than at single, tangential point.This provides more desirable transfer of articles to the adjacent unitbecause the amount of time to transfer the article is increased.

Beneficially, variable-speed starwheels 1100 may be used to achievegreater working angles of adjacent units such as the forming turret 204.For example, variable speed starwheels 1100 can be used to reduce theeffective radius between the infeed and outfeed starwheels in a firstdirection (e.g., between the infeed and outfeed starwheels) relative toa rigid starwheel while maintaining both the pitch between pockets 214and the linear speed of the pockets required at the receiving anddepositing points.

The pockets 214 of the variable-speed starwheels 1100 can include anysuitable mechanism to releasably secure the article to the pocket 214during transport. In some embodiments, the pockets 214 include at leastone vacuum port configured to releasably secure the article to thepocket 214. The vacuum port is coupled to a vacuum source, which isselectively delivered to the pocket 214. For example, in someembodiments, the selective delivery of the vacuum to the pocket 214 iscontrolled by timing valves. In some embodiments, the selective deliveryof the vacuum to the pocket 214 is controlled by plate (e.g., a moveableplate) which inhibits vacuum from being delivered to the pocket 214between certain rotational angles of the variable-speed starwheel 1100.In some embodiments, the pockets 214 include mechanical features toreleasably secure the article to the pocket 214. For example, in someembodiments, a “gripper” is used, to apply a pinching force to thearticle. The mechanical features can be actuated by, for example, a camelement or other non-rotational feature.

Referring now to FIGS. 12A-12C, a flexural hinge mechanism 410 is shown.The flexural hinge mechanism includes first resilient plates 1202 a andsecond resilient plates 1202 b. The first resilient plates 1202 a andsecond resilient plates 1202 b are formed from a material having a highyield strength such as such as spring steel. Beneficially the high yieldstrength allows the resilient plates to maintain their form indefinitelyif the spring stress is kept below the fatigue limit for the material.

The first resilient plates 1202 a are disposed along a line in a firstco-planar arrangement. The second resilient plates 1202 b are disposedalong the line in a second co-planar arrangement. The first co-planararrangement is perpendicular to the second co-planar arrangement suchthat the first resilient plates 1202 a and the second resilient platesgenerally form an “X” pattern when viewed from an end of the bottom moldsegment 402 c. The shared line forms a hinge axis.

The multi-segment mold 308 includes an alignment mechanism. In someaspects, the alignment mechanism includes a plurality of tapered pins422 configured to mate with a plurality of tapered holes 424. In someaspects, each segment includes a tapered pin 422 configured to mate witha respective tapered hole 424 disposed on an adjacent segment. While themold is closing, each of the tapered pins 422 moves into engagement witha respective tapered hole 424. The engagement of the tapered pins 422with the respective tapered holes 424 guides the mold segments 402 a-cinto alignment. Beneficially, the alignment mechanism provides forprecise, repeatable alignment of the segments 402 a-c of themulti-segment mold 308. This precise, repeatable alignment allows forair-tight seals to be formed between the segments 402 a-c of themulti-segment mold 308. Additionally, the precise, repeatable alignmentprovides for production of formed containers with minimal or noaberrations due to seams between segments 402 a-c of the multi-segmentmold 308.

Beneficially, the flexural hinge mechanism 410 provides for rotationalong the hinge axis without drawbacks associated with certain otherhinge mechanisms. For example, the flexural hinge mechanism 410significantly resists wear, has no backlash, does not requirelubrication, and provides increased longevity of the hinges.Additionally, the flexural hinge mechanism 410 does not need the levelof precision in machining required by certain other hinge mechanisms.

Beneficially, use of the alignment mechanism and flexural hingesprovides for easy assembly of the multi-segment mold 308. When themulti-segment mold 308 is assembled, the segments 402 a-c are placedtogether such that the tapered pins 422 and tapered holes 424 areengaged. The flexural hinges 410 are then secured between the bottomsegment 402 c and the respective adjacent segments 402 a,b.

Referring now to FIGS. 13A-13B, a belt-driven loading mechanism 302 isshown. In some aspects, the belt-driven loading mechanism 302 providesan overload reset mechanism. The overload reset mechanism is configuredto inhibit damage to the forming module 208 from, for example, a misfedpreform article 216 and configured to reset the loading mechanism 302 tothe first position when a misfeed occurs. The loading-mechanism carriage344 is guided between the first position and the second position byrails 1302. The rails 1302 include a stop mechanism 1304 such a collar.The loading-mechanism carriage 344 is slidably attached to the belt 346using a clamping mechanism 1306. The clamping mechanism 1306 usesresilient members such as spring washers to provide a clamping pressureto the belt 346. The clamping pressure provides sufficient frictionalforce between the belt 346 and the clamping mechanism 1306 to move theloading-mechanism carriage with the belt 346. When a misfeed occurs, theforce of friction is overcome and the belt 346 continues to move towardthe second position, while the loading-mechanism carriage 344 remainsgenerally motionless. This prevents damage to the forming module 208 byinhibiting the pre-form article 216 from being driven into contact withcomponents of the module. When the loading-mechanism actuator 304 beginsits return, the loading-mechanism carriage 344 is urged toward the firstposition by the belt 346. However, because the belt 346 slid relative tothe loading-mechanism carriage 344, the loading-mechanism carriage 344returns to the first position prior to the loading-mechanism actuator304. Once at the first position, the loading-mechanism carriage 344engages the stop mechanism 1304. The stop mechanism 1304 providesresistive force so that the belt 346 slips through the clampingmechanism 1306. When the loading-mechanism actuator 304 returns to thefirst position, the system is reset to its initial conditions and mayreceive another pre-form container 216.

It is contemplated that a lower-speed, non-rotary system implementingaspects of the present disclosure is also possible. Single or multipleassemblies similar to FIG. 3A can be fed preforms manually, or by anautomated system such as a robot or other device.

It is also contemplated that some aspects of the present disclosure maybe applied to other processes to provide for forming of non-metallicarticles, such as “blow-forming” of polymeric materials. For example,the electromagnetic coil 306 and charging circuit 102 may be replaced bya high pressure pneumatic, hydraulic, or bladder system to pressure formarticles that do not respond well to aspects of above-describedelectromagnetic forming. These articles may include, for example,polymeric materials such as polyethylene terephthalate, polyvinylchloride, polyethylene, polypropylene, metals or metal alloys that donot respond to electromagnetic energy, combinations thereof, and thelike.

It is also contemplated that heat exchangers can be included in theforming system to dissipate heat. In some aspects, the multi-segmentmold may include a plurality of passages configured to have a coolingfluid passed therethrough. These can be used to remove heat built upduring the forming process, as well as alter physical properties of themulti-segment mold to improve forming of the articles. In some aspects,the electromagnetic coil 306 may include a plurality of passagesconfigured to have a cooling fluid passed therethrough. These can beused to remove heat built up during the forming process, as well asalter physical and electrical properties of the electromagnetic coil. Insome aspects, the electromagnetic coil is cooled to lower theresistance, thus increasing electrical efficiency of the formingprocess.

Systems in accord with the present disclosure may also implement aspecialized enclosure to provide one or more functions. In some aspects,certain enclosures may be provided with the system to ventilate fumes ofablated materials. In some aspects, certain enclosures may be providedto maintain an inert environment around one or more portions of thesystem. For example, portions of the system with an open sparktravelling between adjacent contacts can be placed in an environmentincluding nitrogen, carbon dioxide, a vacuum, or another inert materialto inhibit ablation of the contact material. In some aspects, asound-dampening enclosure is provided around portions of the system,such as capacitor banks or contact points, to inhibit noise hazards whenthe system is placed in, for example, a warehouse.

Systems in accord with the present disclosures may also provide forlower cost to manufacture articles by lowering operating costs such asreplacement parts, maintenance, and power requirements.

While the articles herein are described as having an open end opposite aclosed end and at least one sidewall bridging the open end and theclosed end, it is also contemplated that each of the articles may beopen at both ends or closed at both ends. Additionally, a top, lid, orother closure may be added to the articles during an operation by theelectromagnetic-forming system or at a later stage.

Each of the embodiments disclosed herein, and obvious variationsthereof, is contemplated as falling within the spirit and scope of theclaimed invention, which is set forth in the following claims. Moreover,the present concepts expressly include any and all combinations andsubcombinations of the elements and aspects disclosed herein.

Alternative Embodiment A

A rotary-turret system for forming a plurality of formed containers froma respective plurality of pre-form articles using electromagneticenergy, the system comprising:

-   -   a rotary turret having a plurality of forming modules, the        forming modules being disposed about the periphery of the rotary        turret, each forming module including a multi-segment mold        disposed about an electromagnetic coil, the multi-segment mold        having a plurality of segments, each segment including an inner        surface, the plurality of inner surfaces defining a desired        shape of the formed containers, the electromagnetic coil being        configured to impart an electromagnetic force on the pre-form        articles when supplied with electrical energy, the        electromagnetic force configured to urge the pre-form articles        into contact with the inner surfaces of the multi-segment mold        to produce the formed containers;    -   a charging circuit configured to supply the electrical energy to        the rotary turret;    -   a discharge-control mechanism operatively coupled to the rotary        turret and the charging circuit, the discharge-control mechanism        configured to selectively actuate discharge of the electrical        energy from the charging circuit to a predetermined one of the        plurality of forming modules,    -   wherein the rotary turret continually rotates during forming of        the plurality of formed containers.

Alternative Embodiment B

The rotary-turret system of alternative embodiment A, further comprisingan infeed starwheel and an outfeed starwheel, the infeed starwheelconfigured to receive the pre-form articles from an upstream process anddeposit each of the pre-form articles into a respective one of theforming modules, the outfeed starwheel configured to receive the formedcontainers from the forming modules and deliver the formed containers toa downstream process.

Alternative Embodiment C

The rotary-turret system of alternative embodiment A, wherein chargingcircuit includes a capacitor bank.

Alternative Embodiment D

The rotary-turret system of alternative embodiment A, wherein thedischarge-control mechanism includes a moving spark-gap mechanism.

Alternative Embodiment E

The rotary-turret system of alternative embodiment A, wherein theelectromagnetic coil includes helical windings, the helical windingsbeing formed from milling a winding tube.

Alternative Embodiment F

The rotary-turret system of alternative embodiment A, further comprisinga compressed-air system and a vacuum system, the compressed-air systemconfigured to pressurize an internal volume disposed between thepre-form article and the electromagnetic coil to a predeterminedpressure, the vacuum system configured to evacuate a volume between thepre-form article and the inner surface of the multi-segment mold.

Alternative Embodiment G

The rotary turret system of alternative embodiment A, wherein themulti-segment mold has three segments.

Alternative Embodiment H

The rotary turret system of alternative embodiment A, wherein thesegments include hinges coupling the segments of the multi-segment moldsuch that actuating a first segment of the multi-segment mold actuatesthe remaining segments of the multi-segment mold.

Alternative Embodiment I

A method for electromagnetic forming of formed containers using a rotaryturret having a plurality of forming modules disposed about theperiphery of the rotary turret, the method comprising the acts of:

receiving a pre-form article from an upstream process in a respectiveone of the forming modules;

disposing the pre-form article about an electromagnetic coil, theelectromagnetic coil being disposed on the forming module, theelectromagnetic coil being configured to impart an electromagnetic forceon the pre-form article when supplied with electrical energy;

securing a multi-segment mold about the pre-form article, themulti-segment mold including a plurality of segments, each of theplurality of segments including an inner surface, the plurality of innersurfaces defining a desired shape of the formed containers;

supplying, after the securing the multi-segment mold, a first electricalenergy to the electromagnetic coil to produce an electromagnetic force,the electromagnetic force configured to urge the pre-form article intocontact with the inner surfaces of the multi-segment mold, therebyproducing one of the formed containers; and

wherein the disposing, securing, and supplying steps occur while therotary turret continually rotates.

Alternative Embodiment J

The method of alternative embodiment I, further comprising removing theformed container from the respective one of the forming module using anoutfeed starwheel, and wherein the pre-form article is received from aninfeed starwheel.

Alternative Embodiment K

The method of alternative embodiment 1, wherein the electromagnetic coilincludes helical windings, the helical windings being milled from awinding tube.

Alternative Embodiment L

The method of alternative embodiment I, wherein the multi-segment moldhas three segments.

Alternative Embodiment M

The method of alternative embodiment I, wherein the multi-segment moldincludes hinges coupling the segments of the multi-segment mold, andwherein the securing the multi-segment mold is performed by an actuatorengaging a single segment of the plurality of segments.

Alternative Embodiment N

The method of alternative embodiment I, further comprising the acts of:

pressurizing, prior to supplying the first electrical energy, aninterior volume disposed between the pre-form article and theelectromagnetic coil to a predetermined pressure; and

evacuating, prior to the supplying the first electrical energy, a volumedefined by the pre-form article and the inner surfaces of themulti-segment mold.

Alternative Embodiment O

The method of alternative embodiment I, further comprising the act ofsupplying a second electrical energy to the electromagnetic coil toproduce a second electromagnetic force, the second electromagnetic forceconfigured to further urge the pre-form article into contact with theinner surfaces of the multi-segment mold.

Alternative Embodiment P

The method of alternative embodiment 0, wherein the second electricalenergy is higher than the first electrical energy.

Alternative Embodiment Q

The method of alternative embodiment I, wherein the electromagnetic coilis configured to produce a first magnetic domain corresponding to afirst portion of the pre-form article and a second magnetic domaincorresponding to a second portion of the pre-form article, and whereinthe supplying the electrical energy produces the electromagnetic forcein a first magnetic domain and a second electromagnetic force in asecond magnetic domain, the second electromagnetic force being lowerthan the electromagnetic force.

Alternative Embodiment R

A system for forming a plurality of formed containers from a pluralityof pre-form articles using electromagnetic energy, the systemcomprising:

a plurality of forming modules, the plurality of forming modules beingmovably mounted relative to an infeed mechanism, the infeed mechanismconfigured to supply pre-form articles to the plurality of formingmodules, each of the plurality of forming modules including amulti-segment mold disposed about an electromagnetic coil, themulti-segment mold having a plurality of segments, each of the pluralityof segments including an inner surface, the plurality of inner surfacesdefining a desired shape of the formed containers, the electromagneticcoil being configured to impart an electromagnetic force on the pre-formarticles when supplied with electrical energy, the electromagnetic forcebeing configured to urge the pre-form articles into contact with theinner surfaces of the multi-segment mold to produce the formedcontainers;

a charging circuit being configured to supply the electrical energy tothe plurality of forming modules;

a discharge-control mechanism operatively coupled to the plurality offorming modules and the charging circuit, the discharge-controlmechanism being configured to selectively actuate discharge of theelectrical energy from the charging circuit to a predetermined formingmodule.

Alternative Embodiment S

The system of alternative embodiment R, further comprising acompressed-air system and a vacuum system, the compressed-air systembeing configured to pressurize an internal volume disposed between thepre-form article and the electromagnetic coil to a predeterminedpressure, the vacuum system being configured to evacuate a volumebetween the pre-form article and the inner surface of the multi-segmentmold.

Alternative Embodiment T

A mold system comprising:

a first plate disposed opposite a second plate, each of the first plateand the second plate including a plurality of slots thereon, each of theplurality of slots in the first plate corresponding to a respective oneof the plurality of slots on the second plate; and

a multi-segment mold extending the distance between the first plate andthe second plate, the multi-segment mold having an open state and aclosed state, the multi-segment mold including a plurality of segments,each of the plurality of segments having one of a plurality of innersurfaces thereon, the plurality of segments being cooperatively arrangedsuch that the plurality of inner surfaces defines a volume when in theclosed state, each of the plurality of segments of the multi-segmentmold including a first end disposed proximate the first plate and asecond end proximate the second plate, the first end and the second endof each of the plurality of segments including slot followers, each ofthe slot followers being configured to engage one of the plurality ofslots,

wherein each of the plurality of slots is shaped such that engagement ofthe slot followers with the respective slots guide movement of theplurality of segments between the open state and the closed state wheneach of the plurality of segments moves relative to the first plate andthe second plate.

Alternative Embodiment U

The mold system of alternative embodiment T, wherein the multi-segmentmold further includes a plurality of hinges coupling the segments of themulti-segment mold such that actuating a first segment of themulti-segment mold actuates the remaining segments of the multi-segmentmold.

Alternative Embodiment V

The mold system of alternative embodiment T, wherein each of theplurality of segments further includes one of a plurality of inserts,each of the plurality of inner surfaces being disposed on a respectiveone of the plurality of inserts.

Alternative Embodiment W

The mold system of alternative embodiment T, wherein the plurality ofsegments further comprises a plurality of apertures extendingtherethrough, the plurality of apertures being coupled to a vacuumsystem, the plurality of apertures being configured to evacuate air froma volume between the plurality of inner surfaces and the pre-formarticle.

Alternative Embodiment X

The mold system of alternative embodiment T, wherein the plurality ofinner surfaces includes an embossing pattern thereon.

Alternative Embodiment Y

The mold system of alternative embodiment T, further comprising anelectromagnetic coil disposed within the volume when the multi-segmentmold is in the closed position, the electromagnetic coil beingconfigured to urge a pre-form article into contact with the plurality ofinner surfaces.

Alternative Embodiment Z

An electromagnetic coil assembly comprising:

a bottom cap and milled helical windings, the milled helical windingsbeing electrically coupled to the bottom cap, the bottom cap and themilled helical windings being configured to be coupled to a chargingcircuit, the helical coil being configured to exert an electromagneticforce when an electrical energy is passed through the milled helicalwindings,

wherein the milled helical windings are created by milling a generallycylindrical tube of conductive material.

Alternative Embodiment AA

The electromagnetic coil assembly of alternative embodiment Z, whereinthe helical windings define a cavity, the helical windings havingcross-sectional profiles including generally flat edges proximate thecavity.

Alternative Embodiment BB

The electromagnetic coil assembly of alternative embodiment AA, whereinthe cross-sectional profile is generally rectangular.

Alternative Embodiment CC

The electromagnetic coil assembly of alternative embodiment Z, whereinthe bottom cap is generally shaped to extend into a domed bottom of apre-form article when the pre-form article is disposed about theelectromagnetic coil assembly.

Alternative Embodiment DD

A method of making an electromagnetic coil comprising the acts of:

assembling a winding tube, a bottom cap, and a return conductor, theassembling including

-   -   securing the bottom cap to an end of the winding tube, the        bottom cap being electrically coupled to the winding tube, and    -   securing the return conductor to the bottom cap, the return        conductor being electrically coupled to the bottom cap;

pouring a curable material into a cavity formed by the winding tube, thebottom cap, and the return conductor; and

milling the winding tube to form helical windings, the windings beingformed by removing portions of the winding tube.

Alternative Embodiment EE

The method of alternative embodiment DD, wherein each of the helicalwindings has a generally rectangular cross-sectional profile.

Alternative Embodiment FF

The method of alternative embodiment DD, wherein the helical windingshave a non-uniform pitch along the length of the electromagnetic coil,the non-uniform pitch creating a plurality of electromagnetic domainswhen an electrical energy is passed through the electromagnetic coil.

Alternative Embodiment GG

The method of alternative embodiment DD, wherein the bottom cap isshaped to accommodate a domed bottom of a pre-form article.

Alternative Embodiment HH

The method of alternative embodiment GG, further comprising the act ofmilling at least one passage in the bottom cap, the at least one passagebeing configured to allow airflow between the bottom cap and an exteriorof the helical windings.

Alternative Embodiment II

An electromagnetic coil comprising:

a bottom cap being shaped to accommodate a domed bottom of a pre-formarticle;

helical windings extending from the bottom cap, the helical windingsdefining a generally cylindrical cavity therein, each of the helicalwindings having a cross-sectional profile, the cross-sectional profilesincluding generally flat edges proximate the cavity;

a return conductor electrically coupled to the bottom cap such that thehelical windings, bottom cap, and return conductor form an electricalcircuit, the electrical circuit configured to be electrically coupled toa charging circuit.

Alternative Embodiment JJ

The electromagnetic coil of alternative embodiment II, wherein thecross-sectional profile is generally rectangular.

Alternative Embodiment KK

The electromagnetic coil of alternative embodiment II, wherein thehelical windings include a plurality of parallel electrical pathsbetween the bottom cap and the power source.

Alternative Embodiment LL

The electromagnetic coil of alternative embodiment II, wherein thehelical windings form a plurality of electromagnetic domains along thelength of the coil.

Alternative Embodiment MM

The electromagnetic coil of alternative embodiment LL, wherein theelectromagnetic domains are formed by a non-uniform pitch of the helicalwindings.

Alternative Embodiment NN

The electromagnetic coil of alternative embodiment II, wherein thehelical windings and the bottom cap form a generally tapered edge suchthat the helical windings extend proximate a bottom edge of the pre-formarticle when the pre-form article is disposed about the electromagneticcoil.

Alternative Embodiment OO

The electromagnetic coil of alternative embodiment NN, wherein adistance from the helical windings to the bottom edge is less than about25 mm.

Alternative Embodiment PP

The electromagnetic coil of alternative embodiment NN, wherein adistance from the helical windings to the bottom edge is less than about20 mm.

Alternative Embodiment OO

The electromagnetic coil of alternative embodiment NN, wherein adistance from the helical windings to the bottom edge is less than about15 mm.

Alternative Embodiment RR

The electromagnetic coil of alternative embodiment II, wherein thecavity includes a rigid core disposed therein, the core being configuredto inhibit movement of the helical windings during application of anelectromagnetic energy.

Alternative Embodiment SS

The electromagnetic coil of alternative embodiment RR, wherein the coreis formed from a poured epoxy, urethane, or polyurethane resin.

Alternative Embodiment TT

The electromagnetic coil of alternative embodiment II, wherein theassembly is configured to be coupled to a compressed-air system, thecompressed-air system being configured to pressurize an internal volumedisposed between the pre-form article and the electromagnetic coil to apredetermined pressure when the pre-form article is disposed about thehelical windings.

Alternative Embodiment UU

The electromagnetic coil of alternative embodiment TT, furthercomprising a plurality of sealing members disposed about the helicalwindings proximate the top cap, the sealing members being configured toform a substantially air-tight seal between a portion of the pre-formarticle and the electromagnetic coil assembly.

Alternative Embodiment VV

The electromagnetic coil of alternative embodiment II, furthercomprising a sleeve disposed about the helical windings, the sleevebeing configured to electrically insulate the electromagnetic coil fromthe pre-form article.

Alternative Embodiment WW

A variable-speed starwheel for transferring articles comprising

a driving mechanism configured to rotate about an axis of rotation;

a cam surface having variable radial distance from the axis of rotation,the variable radial distance having a first radial distance extending afirst distance away from the axis of rotation at a first angularposition, and a second radial distance extending a second distance awayfrom the axis of rotation at a second angular position, the secondangular position being spaced a distance from the first angularposition; and

an arm coupled to the driving mechanism, the arm including a pivotmechanism, a pocket, and a cam follower, the pivot mechanism beingcoupled to the driving mechanism, the pivot mechanism providingpivotable movement of the arm relative to the driving mechanism, thepivot mechanism being spaced a distance from the pocket, the pocketbeing configured to releasably receive the articles, the cam followerbeing configured to engage the cam surface,

wherein engagement of the cam follower with the cam surface at the firstangular position disposes the arm at a first angle, and whereinengagement of the cam follower with the cam surface at the secondangular position disposes the arm at a second angle, the second anglebeing different than the second angle.

Alternative Embodiment XX

The variable-speed starwheel of alternative embodiment WW, wherein thedriving mechanism includes a motor.

Alternative Embodiment YY

The variable-speed starwheel of alternative embodiment WW, wherein thedriving mechanism includes a synchronization mechanism.

Alternative Embodiment ZZ

The variable-speed starwheel of alternative embodiment WW, wherein thearm is configured to nest with an adjacent arm of the variable-speedstarwheel.

Alternative Embodiment AAA

The variable-speed starwheel of alternative embodiment WW, wherein thecam follower is axially offset from the pivot mechanism such thatmovement of the cam follower does not interfere with movement of anadjacent arm.

Alternative Embodiment BBB

An arm for use in a variable-speed starwheel to transfer articles, thearm comprising:

a member having a first end opposite a second end, the first end havinga pivot mechanism configured to be coupled to a driving mechanism, thepivot mechanism being configured to provide pivotable movement of thearm relative to the driving mechanism, the second end having a pocketconfigured to releasably receive the articles; and

a cam follower configured to engage a cam surface, the cam followerbeing coupled to the member such that engagement of the cam followerwith a cam surface is configured pivotably move the arm about the pivotmechanism.

Alternative Embodiment CCC

The arm of alternative embodiment BBB, wherein the cam follower iscoupled to the member using a support, the support being attached to themember between the first end and the second end.

Alternative Embodiment DDD

The arm of alternative embodiment BBB, wherein the cam follower isdisposed proximate the pivot mechanism and distal the pocket.

Alternative Embodiment EEE

A variable-speed starwheel for transferring articles comprising:

a driving mechanism configured to rotate about an axis of rotation;

a cam surface having variable radial distance from the axis of rotation,the variable radial distance having a first radial distance extending afirst distance away from the axis of rotation at a first angularposition, and a second radial distance extending a second distance awayfrom the axis of rotation at a second angular position, the secondangular position being spaced a distance from the first angularposition; and

an arm coupled to the driving mechanism, the arm including a firstportion and a second portion, the second portion being slidably mountedon the first portion, the first portion being attached to the drivingmechanism, the second portion including a pocket and a cam follower, thepocket being configured to releasably receive the articles, the camfollower being configured to engage the cam mechanism.

wherein engagement of the cam follower with the cam surface at the firstangular position disposes the arm at a first distance from the axis ofrotation, and wherein engagement of the cam follower with the camsurface at the second angular position disposes the arm at a seconddistance from the axis of rotation, the first distance being differentthan the second distance.

Alternative Embodiment FFF

A variable-speed starwheel for transferring articles comprising:

a driving mechanism configured to rotate about an axis of rotation;

a pocket coupled to the driving mechanism, the pocket being configuredto releasably receive the articles; and

a movement means, the movement means being configured to dispose thepocket at a first distance from the axis of rotation when the pocket isat a first angular position and to dispose the pocket at a seconddistance from the axis of rotation when the pocket is at a secondangular position.

Alternative Embodiment GGG

The variable-speed starwheel of alternative embodiment GGG, wherein themovement means includes a cam follower configured to engage a camsurface, the cam follower being attached to the pocket.

What is claimed is:
 1. A mold system comprising: a first plate disposedopposite a second plate, each of the first plate and the second plateincluding a plurality of slots thereon, each of the plurality of slotsin the first plate corresponding to a respective one of the plurality ofslots on the second plate; and a multi-segment mold extending thedistance between the first plate and the second plate, the multi-segmentmold having an open state and a closed state, the multi-segment moldincluding a plurality of segments, each of the plurality of segmentshaving one of a plurality of inner surfaces thereon, the plurality ofsegments being cooperatively arranged such that the plurality of innersurfaces defines a volume when in the closed state, each of theplurality of segments of the multi-segment mold including a first enddisposed proximate the first plate and a second end proximate the secondplate, the first end and the second end of each of the plurality ofsegments including slot followers, each of the slot followers beingconfigured to engage one of the plurality of slots, wherein each of theplurality of slots is shaped such that engagement of the slot followerswith the respective slots guide movement of the plurality of segmentsbetween the open state and the closed state when each of the pluralityof segments moves relative to the first plate and the second plate. 2.The mold system of claim 1, wherein the multi-segment mold furtherincludes a plurality of hinges coupling the segments of themulti-segment mold such that actuating a first segment of themulti-segment mold actuates the remaining segments of the multi-segmentmold.
 3. The mold system of claim 1, wherein each of the plurality ofsegments further includes one of a plurality of inserts, each of theplurality of inner surfaces being disposed on a respective one of theplurality of inserts.
 4. The mold system of claim 1, wherein theplurality of segments further comprises a plurality of aperturesextending therethrough, the plurality of apertures being coupled to avacuum system, the plurality of apertures being configured to evacuateair from a volume between the plurality of inner surfaces and thepre-form article.
 5. The mold system of claim 1, wherein the pluralityof inner surfaces includes an embossing pattern thereon.
 6. The moldsystem of claim 1, further comprising an electromagnetic coil disposedwithin the volume when the multi-segment mold is in the closed position,the electromagnetic coil being configured to urge a pre-form articleinto contact with the plurality of inner surfaces.